Trackless AGV with Scissor Lifting Industrial Handling Cart

Production Challenge
A large production workshop of a heavy machinery manufacturer faced long-standing issues with traditional rail guided transfer carts, which involved high installation costs and fixed routes, unable to meet the flexible transfer needs for multiple product types. Narrow workshop aisles limited turning radius, leading to frequent material pile-ups. The daily effective transfer frequency was less than 30 times.

Solution
Addressing these pain points, we designed and manufactured this 5 tons lithium battery powered trackless automated guided vehicle (AGV) for the client.

• AGV features a cast steel spliced frame and mecanum wheel drive system, enabling 360° in-place turning with a minimum turning radius of only 1.8 meters.
• Equipped with a scissor lifting platform and an intelligent coding control system, it achieves autonomous workpiece loading and unloading without manual assistance.
• Powered by a lithium battery and portable charging station, vehicle offers 8 hours of operation per charge, with operational stability in high-temperature environments (≤60°C) enhanced to 99.2%.
• Integrated with laser dead man stop and safety bumpers for dual protection, response time is ≤0.5 seconds.
• Audible and visual warning lights and an LED display provide real-time operational status feedback, supporting dual-mode switching between wireless remote control and manual operation.

Advantages
High Efficiency and Flexibility: Wireless remote control combined with intelligent path planning reduces manual intervention, increasing transfer efficiency by 40%.
Strong Adaptability: Made of high temperature resistant materials with a heavy-duty structure, it operates stably in high temperature, dusty areas like foundry workshops.
Safety and Controllability: Features real-time battery level display and status monitoring (via LED screen), one-click emergency braking, reducing failure rate by 60%.

Application
This AGV is deployed between the foundry line and assembly line, handling the transfer of heavy components like engine blocks. Operators issue commands via wireless remote control. The AGV autonomously travels to the loading point, where its lifting platform cooperates with hydraulic positioning devices to complete autonomous pickup. It then transports the load along a preset path to the next workstation. During operation, audible and visual warnings automatically alert pedestrians, and the system prompts for charging zone replenishment when battery is low.

After deploying the AGV, the workshop achieved:
Cost Reduction and Efficiency Gain: Reduced manpower requirement by 2 forklift operators and shortened material turnover time by 35%.
Space Saving: Eliminated need for fixed tracks, reducing required aisle width by 30% and improving space utilization.
Green and Smart Manufacturing: Zero-emission electric drive and low-noise operation align with environmental requirements, assisting the company in obtaining ISO14001 certification.