Automated Guided Vehicles (AGVs) have become an important part of modern manufacturing and intralogistics. They automate material transportation between production lines, warehouses, workstations, and storage areas, helping manufacturers improve efficiency, safety, and operational flexibility.

With so many AGV configurations available, choosing the right solution can be challenging. A practical way to understand AGVs is to look at two fundamental aspects:

How does the AGV handle materials?

How does the AGV navigate?

This guide introduces the common types of AGVs, the major navigation technologies, and the key factors to consider when selecting an AGV for an industrial application.

1. Common Types of AGVs by Material Handling Method

The material handling method determines how an AGV interacts with the load and what type of application it is suitable for.

Under-Ride Lift AGV

Under-ride lift AGVs are widely used in automated warehouses and goods-to-person logistics systems.

The AGV travels underneath a storage rack and uses an integrated lifting mechanism to raise the rack before transporting it to another location.

Typical payloads range from approximately 0.5 to 2 tons. These AGVs are commonly used in e-commerce warehouses, distribution centers, and automated storage systems.

Towing AGV

Towing AGVs transport materials by pulling one or more carts behind the vehicle rather than carrying the load directly.

They are particularly suitable for long-distance material transportation, line-side delivery, and applications where multiple material carts need to be transported together.

Towing AGVs can provide high transportation efficiency, especially in manufacturing environments with relatively stable transportation routes.

Forklift AGV

Forklift AGVs are equipped with forks that allow them to automatically pick up, transport, and stack pallets.

They are designed to automate many of the material handling tasks traditionally performed by manual forklifts.

Typical payload capacities range from 1 to 3 tons or more, depending on the vehicle configuration. Forklift AGVs are widely used in pallet warehouses, production logistics, and high-bay storage applications.

Carrier and Roller AGV

Carrier AGVs transport materials directly on their platforms, rollers, or conveyor systems.

They can automatically dock with production lines, conveyors, and other material handling equipment, enabling automated transfer between different processes.

These AGVs are commonly used in manufacturing plants and automated production lines where reliable material transfer is required.

Heavy-Duty AGV

Heavy-duty AGVs are designed for transporting loads ranging from several tons to dozens of tons.

Typical applications include heavy machinery, molds, steel components, automotive parts, large workpieces, and other industrial materials.

Compared with conventional AGVs, heavy-duty vehicles place significantly higher demands on the AGV drive system. The drive wheels, motors, gearboxes, servo drives, chassis structure, and control system must work together to provide sufficient traction, stability, and reliability.

For heavy-load applications, selecting the right AGV drive wheel is particularly important because wheel load capacity, traction, torque, steering performance, and mechanical durability directly affect overall vehicle performance.

Mobile Manipulator AGV

A mobile manipulator combines an AGV platform with a robotic arm.

This configuration allows the vehicle to move between different workstations while performing tasks such as machine tending, loading and unloading, assembly, and material handling.

Mobile manipulators provide a high level of flexibility and are increasingly used in flexible manufacturing and intelligent production environments.

For applications requiring high payloads or continuous operation, the performance of the AGV drive system becomes especially important.

Yikong provides heavy-duty AGV drive wheels and low-voltage servo drive solutions for demanding industrial applications.

For example, the TEC series heavy-duty differential drive wheels use independent dual-motor control and encoder feedback to improve driving stability and control performance under heavy loads.

A reliable drive system can help reduce wheel wear, improve vehicle stability, and minimize the risk of deviation during operation.

2. Common AGV Navigation Technologies

The navigation technology determines how an AGV identifies its position, follows its route, and adapts to changes in the working environment.

Different navigation technologies have different advantages and limitations.

Magnetic Navigation

Magnetic navigation uses magnetic tape or magnetic markers installed on the floor to guide the AGV along predefined routes.

Its main advantages include relatively low cost, simple implementation, and stable operation.

However, routes are relatively fixed. If the factory layout changes, the magnetic guidance system may need to be modified accordingly.

Magnetic navigation is suitable for applications with stable transportation routes and clearly defined operating areas.

Laser SLAM Navigation

Laser SLAM navigation uses LiDAR to scan the surrounding environment while simultaneously performing mapping and localization.

Unlike magnetic navigation, it does not require physical guidance lines to be installed on the floor.

This makes SLAM-based navigation highly flexible and suitable for factories and warehouses where transportation routes may change frequently.

Laser SLAM has become one of the most widely used navigation technologies for modern mobile robots and AGVs.

Laser Reflector Navigation

Laser reflector navigation uses reflectors installed at fixed locations around the operating environment.

The AGV measures the position of these reflectors and calculates its own position using laser-based positioning algorithms.

This technology can provide high positioning accuracy and is suitable for applications requiring precise docking with workstations or equipment.

However, the reflectors need to remain clean and unobstructed. Dust or contamination may affect positioning performance and therefore requires regular inspection and maintenance.

QR Code Navigation

QR code navigation uses visual markers installed on the floor.

The AGV scans the QR codes to determine its position and correct its movement.

One advantage is that route changes can be implemented relatively easily by changing the positions of the QR codes.

QR code navigation can provide high positioning accuracy, but floor-mounted codes may become worn or damaged over time and require periodic maintenance or replacement.

Vision Navigation

Vision navigation uses cameras to identify environmental features, floor markings, or other visual references.

It provides a flexible navigation solution without requiring extensive physical infrastructure.

However, performance can be affected by lighting conditions, reflections, floor patterns, and changes in the surrounding environment.

For this reason, environmental conditions should be carefully evaluated before selecting a vision-based navigation system.

Hybrid Navigation

Hybrid navigation combines multiple positioning technologies, such as SLAM, QR codes, inertial navigation, laser positioning, or other sensors.

By combining different technologies, hybrid navigation can provide a balance between positioning accuracy, route flexibility, and environmental adaptability.

It is particularly suitable for complex industrial environments where a single navigation technology may not be sufficient.

Yikong has developed solutions covering magnetic navigation, laser navigation, and SLAM-based navigation technologies.

Combined with AGV drive wheels and servo drive systems, these technologies form an integrated motion and navigation solution for different AGV applications.

3. How to Select the Right AGV

Understanding the different AGV types is only the first step.

The right AGV should be selected according to the actual operating environment, load requirements, transportation process, positioning accuracy, and system integration requirements.

Here are four key steps to consider.

Step 1: Determine the Payload and Material Handling Method

Start with the load and transportation process.

For pallet transportation, forklift AGVs or under-ride lift AGVs may be suitable.

For long-distance transportation using multiple carts, towing AGVs are often a practical choice.

For heavy workpieces, molds, machinery, or other large loads, a dedicated heavy-duty AGV may be required.

At this stage, the AGV drive wheel should also be evaluated according to the required wheel load, traction, torque, operating speed, and floor conditions.

Step 2: Determine the Required Positioning Accuracy

The required positioning accuracy depends on the application.

If the AGV only needs to transport materials between general locations, a standard navigation solution may be sufficient.

If the vehicle needs to dock precisely with production equipment, conveyors, storage systems, or workstations, a higher-accuracy navigation technology may be required.

Laser reflector navigation, QR code navigation, and hybrid navigation can be considered for applications with higher positioning requirements.

Step 3: Evaluate the Operating Environment

Environmental conditions have a direct impact on AGV performance.

Dust and particles may affect LiDAR-based navigation.

Metal structures and electromagnetic interference may influence certain magnetic navigation applications.

Lighting conditions can affect vision-based navigation.

Other factors should also be considered, including:

• Floor conditions
• Temperature and humidity
• Ramps and slopes
• Narrow aisles
• Obstacles
• Traffic density
• Required operating speed
• Continuous operating hours

For harsh industrial environments, the AGV drive system should also be selected according to the required protection level, temperature range, load conditions, and duty cycle.

Step 4: Consider System Integration

An AGV does not operate as an isolated device.

For a complete automated logistics system, the AGV needs to communicate with warehouse management systems, warehouse control systems, charging stations, production equipment, and fleet management systems.

Effective system integration allows multiple vehicles to coordinate their movements, optimize transportation tasks, and reduce congestion and unnecessary waiting.

A complete AGV solution therefore requires more than a vehicle and a navigation system. The drive system, navigation system, motion controller, fleet management software, and peripheral equipment all need to work together.

4. Why the AGV Drive System Matters

Among all AGV components, the drive system is one of the most important factors affecting vehicle performance.

The AGV drive system typically includes the drive wheel, motor, gearbox, servo drive, encoder, and motion control system.

For light-duty AGVs, the main requirements may focus on compact design, efficiency, and maneuverability.

For heavy-duty AGVs, the requirements become significantly more demanding.

The drive system needs to provide:

• High load capacity
• High torque
• Reliable traction
• Accurate speed control
• Stable steering or differential control
• Long operating life
• Low maintenance requirements
• Reliable performance under continuous operation

This is why the AGV drive wheel should not be selected independently from the rest of the vehicle.

The wheel, motor, gearbox, servo drive, chassis, and control system should be considered as an integrated motion solution.

Yikong focuses on AGV drive wheels, servo drive systems, navigation technologies, and other core motion control components.

Our product portfolio covers different AGV configurations and operating requirements, from standard material handling vehicles to heavy-duty mobile robots.

5. From AGV Components to Complete Motion Solutions

Selecting an AGV is ultimately about matching the technology to the application.

Different loads require different vehicle structures.

Different environments require different navigation technologies.

Different positioning requirements require different control and sensing systems.

And different payloads and operating conditions require different AGV drive wheel and motion control configurations.

Yikong provides core components and customized solutions for AGV and mobile robot applications, including:

• AGV Drive Wheels
• Differential Drive Wheels
• Heavy-Duty Drive Wheels
• Servo Motors
• Servo Drives
• Navigation Systems
• Motion Control Solutions
• Customized AGV Drive Systems

By combining drive, control, and navigation technologies, Yikong supports AGV manufacturers, system integrators, and industrial automation companies in developing reliable mobile robot solutions.

Conclusion

AGVs can be classified from many different perspectives, but two questions provide a practical starting point:

How does the AGV handle materials?

How does the AGV navigate?

From under-ride lift AGVs and forklift AGVs to towing and heavy-duty AGVs, different vehicle configurations are designed for different transportation requirements.

Likewise, magnetic navigation, laser SLAM, laser reflector navigation, QR code navigation, vision navigation, and hybrid navigation each have their own advantages and application scenarios.

The best AGV is not necessarily the most advanced or the most expensive one. The right solution is the one that matches the actual application requirements.

Payload, transportation method, positioning accuracy, operating environment, drive system, navigation technology, and system integration should all be evaluated together.

With expertise in AGV drive wheels, servo drives, navigation systems, and motion control technologies, Yikong provides the core technologies needed to help AGV manufacturers and system integrators build reliable and efficient mobile robot solutions.