AGV Integration & Retrofitting

Vehicle delivered but not running? Carrier doesn't fit your parts? No interface to the line? We don't sell vehicles — we make them work on your floor.

AGV deployment partner that understands production lines
Sound Familiar?
Buying an AGV is easy. Making it run reliably in a real factory is not. These are the problems we get called in to solve.
AGV bought, but it won't interlock with line equipment
Vehicle suppliers only guarantee the vehicle moves. Signal exchange, interlock logic and fault handling are left to nobody. We deliver the complete PLC-level interface and commissioning.
Standard carriers don't fit our workpieces
Irregular shapes, offset centre of gravity, parts needing rotation or positioning. We design and build custom carriers: jacking units, roller conveyors, grippers and dedicated pallets.
Positioning accuracy too low for robot pick-up
AGVs typically stop within ±10 mm. We add vision-guided secondary positioning to compensate, bringing effective accuracy to a level robots can pick from directly.
Multiple vehicles congest and throughput stalls
Path planning and traffic-control parameters were never tuned. We measure actual cycle times on site, then re-plan routes, manage intersections and optimise dispatch strategy.
Retrofitting an existing line without long downtime
Phased rollout: carriers and line interfaces pre-fabricated off-line, cutover in weekend windows, single-station pilot validation — downtime kept to a minimum.
Upper-level systems won't talk to each other
MES issues work orders, WMS manages locations, and the AGV fleet manager runs its own island. We build the middleware so tasks flow automatically without manual dispatch.
What We Do
Full capability from selection to handover — or a single service dropped into an existing project.

🎯 AGV Selection Consulting

We match vehicle type and navigation method to your payload, cycle time, aisle width, floor condition and accuracy requirements, then provide comparable options with budget ranges. Brand-independent.

🔧 Custom Carrier Retrofitting

Jacking mechanisms, roller and chain conveyors, dedicated grippers, custom pallets, rotation and positioning units. In-house mechanical design and machining — from 3D model to assembly and commissioning.

Core Strength

🛠️ Chassis Modification

Chassis reinforcement, mounting a collaborative arm to form a composite robot (AMR + arm), lift-stroke modification, guarding and safety accessories.

🔌 PLC Signal Interfacing

IO and fieldbus interaction design between AGVs and line equipment, buffers, doors, lifts and conveyors. PLC programming and interlock safety logic on Mitsubishi, Siemens, Inovance and other mainstream platforms.

📊 MES / WMS Integration

Work-order-driven transport tasks, synchronised location and WIP data, task status feedback. Middleware development that genuinely connects upper-level systems with the fleet manager.

👁️ Vision-Guided Precision Positioning

Cameras determine the actual pose of the workpiece or bin and compensate AGV stop deviation in real time, enabling teach-free robot pick and place. This is where our vision expertise gives AGVs an edge.

Differentiator

🚦 Fleet Scheduling Optimisation

Route re-planning, intersection traffic control, priority and charging strategy, cycle-time simulation. Fixes congestion and throughput shortfalls after go-live.

🏗️ Installation & Maintenance

QR-code application, magnetic tape and reflector installation, charging station and network deployment, safety zone planning. Operator training, spare parts and long-term support after handover.

Choosing a Navigation Method
Navigation method determines retrofit effort, accuracy and future flexibility. This is the comparison we actually use when advising clients.
NavigationAccuracySite WorkFlexibilityBest Suited For
Laser SLAM±10 ~ ±30mmVirtually noneHigh — edit the map, change the routeFrequently reconfigured lines, high-mix low-volume, environments with recognisable contours
QR Code±5 ~ ±10mmModerate — floor codes appliedMedium — new codes neededFixed routes, dense storage, high stop-position repeatability required
Magnetic Tape / Spot±5 ~ ±10mmSlotting or bonding requiredLow — rerouting means floor workPermanently fixed routes, heavy dust or oil, budget sensitive
Reflector Laser±5 ~ ±10mmReflectors to be installedMediumHigh-accuracy docking, large-span plants, AS/RS in-feed and out-feed
Vision + Inertial Hybrid±2 to ±5 mm (with vision secondary positioning)LowHighRobot load handling, precision docking stations

※ Figures are typical vehicle stop-position accuracies; actual values depend on the selected model specification and on-site measurement. Vision-based secondary positioning further improves effective docking accuracy.

Typical Applications
Site footage is being added. Contact us for a detailed solution description for any of these scenarios.
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Site video · coming soon

Automated Material Delivery

Scheduled or on-call delivery of raw material from stores to workstations, replacing manual forklifts and tuggers. Triggered by call buttons, kanban systems or MES work orders.

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Site video · coming soon

Inter-Process WIP Transfer

Automatic WIP transfer between processes with unattended handover to line conveyors. Roller or jacking carriers enable automatic bin loading and unloading.

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Site video · coming soon

AS/RS and Line Interfacing

AGVs work with automated storage, stacker cranes and WMS to close the in-feed and out-feed loop. Reflector or QR navigation ensures docking accuracy.

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Site video · coming soon

Vision-Guided Robot Load Handling

Once the AGV is in position, vision determines the actual pose of parts in the bin and guides the robot to pick without teaching. Suited to high-mix mixed-flow production.

Implementation Process
Typically 4–10 weeks from survey to handover, depending on retrofit scope and available downtime.
1

Site Survey

Measure aisles, floor, cycle times and part conditions; identify equipment and signals to interface

2

Solution Design

Vehicle and navigation selection, carrier design, route and dispatch planning, quotation

3

Carrier Build

Custom carrier fabrication, chassis modification, vision and control integration

4

Commissioning

Mapping and marker layout, PLC/MES commissioning, cycle-time measurement and safety validation

5

Training & Handover

Operator and maintenance training, documentation handover, support arrangements

Stuck on an AGV Project?

Whether you are still selecting a vehicle or one has arrived and won't run, send us your situation for a free assessment.

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