AGVs follow fixed, guided routes while AMRs use onboard sensors and mapping to plan their own paths, and that one difference drives cost, flexibility, and facility requirements. This second part of our warehouse automation series (see Part 1: Pick-to-Light Systems if you missed it) compares both vehicle types and lists the mechanical components used to build them.
AGVs (Automatic Guided Vehicles)
An AGV is just what the name implies: a vehicle that operates on a fixed and guided route. AGVs are mobile robots, such as driverless trains, pallet trucks, or unit load carriers, that can move independently of an operator. How an AGV navigates the warehouse floor depends on its type. Generally, these machines either follow markers or wires in the floor or use a combination of LiDAR (Light Detection and Ranging) sensors to establish routes and avoid obstacles.
Key point: An AGV’s route is set up in advance. That makes its path predictable and repeatable, but changing the route means changing the guidance, whether that is floor markers, wires, or the route programmed into its sensors.
AMRs (Autonomous Mobile Robots)
An AMR is an autonomous robot designed to self-navigate and work collaboratively with humans, offering a much smarter solution than an AGV. You get a flexible solution that adjusts easily to changes in your operational needs. Implementation of an AMR is much simpler than an AGV, because there is no need for expensive facility modifications to automate a warehouse.
An AMR is also far more sophisticated. Many sensors and onboard computers allow it to understand its operating environment. Rather than being restricted to fixed routes, an AMR can navigate using mapping technology, so it can plan its own paths and travel quickly and efficiently. Using LiDAR sensors as well, AMRs can recognize and react to people, cars, forklifts, and more, safely doing their jobs no matter how busy the surrounding environment is. They can even perform tasks like following a person wherever they go.
AGV vs. AMR Comparison
The two may look similar, but several factors set them apart. The biggest difference is how each one moves through a facility.
| Factor | AGV | AMR |
|---|---|---|
| Navigation | Fixed, guided route | Self-navigates using mapping technology |
| Route planning | Follows markers, wires, or a LiDAR-established route | Plans its own paths |
| Flexibility | Limited by the guided route | Easy adjustments when operational needs change |
| Facility modifications | May require modifications, depending on guidance type | No expensive facility modifications needed |
| Awareness of surroundings | Uses LiDAR to establish routes and avoid obstacles | Uses sensors and onboard computers to recognize and react to people, cars, and forklifts |
| Working with people | Moves independently of an operator | Works collaboratively with humans, including following a person |
| Typical forms | Driverless trains, pallet trucks, unit load carriers | Self-driving vehicles and carts |
- Predictable, repeatable routes
- Well suited to stable, high-repeat transport paths
- Can move loads without an operator
- Plans its own paths and adapts to change
- Simpler implementation, no expensive facility changes
- Recognizes and reacts to people and vehicles
How AGVs and AMRs Navigate
Markers in the floor
Some AGVs follow markers placed on or in the floor. The route is defined by the markers, so changing it means moving them.
Wires in the floor
Other AGVs follow wires installed in the floor. This is a fixed, guided route that does not change on its own.
LiDAR route establishment
LiDAR (Light Detection and Ranging) sensors can be used alone or in combination with other guidance to establish routes and avoid obstacles.
Map-based navigation
AMRs use mapping technology, onboard sensors, and onboard computers to understand their environment and plan their own paths.
Engineering note: LiDAR measures distance by timing reflected light. Because it supports both route establishment and obstacle detection, a rigid, well-aligned sensor mount matters. Chassis flex or a loose bracket can shift where the robot “thinks” obstacles are.
The Benefits of Warehouse Robotic Systems
Increased safety
In general, these systems increase workplace safety by keeping workers away from dangerous tasks. Vision systems and laser sensors built into them also help avoid accidents in and around the work environment.
Faster order and delivery times
Robots transport orders to facilities, picking robots, pallet, packaging and pricing departments, loading docks, and shipping containers. The rise of autonomous vehicles and drone delivery concepts may further reduce customer delivery times.
Better use of floor space
Automating production lines reduces the work area footprint. Freed-up floor space can be used for other processes or to expand production lines.
Reduced logistics costs
Greater use of robots in warehouses means a reduced need for human labor, which helps companies reduce overhead costs.
Improved quality
Warehouse robots perform applications repeatedly and with precision every time, so products are handled to similar specifications and processes. That leads to system reliability and fewer repairs.
Reduced workforce burden
As robots take over much of the physical work, workers can move on to more fulfilling and insightful positions. Robots may also allow people who cannot work in traditional logistics operations to find employment in maintaining the units.
Fewer transportation delays
AGVs, AMRs, autonomous trucks, driverless vehicles, and drones can help reduce shipment delays through quick analysis of factors like traffic conditions and weather.
Building or upgrading a mobile robot chassis or drive train?
Shop Timing Belts & Pulleys Browse Aluminum ExtrusionEngineering and Design Considerations
Whether you are building an AGV or an AMR, the mechanical design questions are largely the same. These are the ones to settle first.
Size the drive for the worst case
Size motors and gearing for the heaviest load, the steepest ramp, and the fastest acceleration the vehicle will see, then add a safety factor.
Torque per driven wheel T = (F · r) ÷ (n · η)
m = loaded mass, g = gravity, Crr = rolling resistance coefficient, θ = ramp angle, a = acceleration, r = wheel radius, n = number of driven wheels, η = drivetrain efficiency
Choose a motion-transmission layout
Timing belts and pulleys give positive, non-slip power transmission between motor and wheel. Drive wheels are typically carried on rotary shafts or cantilever shafts supported by ball and roller bearings, with shaft supports and bushings where sliding or pivoting motion is needed. Passive wheels can use casters.
Build a rigid, modular chassis
A frame of aluminum extrusion or factory frames makes it easy to reposition batteries, sensors, and payload fixtures during development. Gussets and angle plates, posts and struts, and machined sheet metal keep the structure square. Mounting LiDAR and other sensors to rigid structure helps keep readings consistent.
Add safety and status signaling
E-stop switches give a hard stop, while stack lights and warning and signaling lights show vehicle status to nearby workers. Sensors and switches and timers handle detection and sequencing.
Safety: AGVs and AMRs share space with people, forklifts, and other equipment. Base the design on your site’s risk assessment and the applicable standards for driverless industrial vehicles, such as ANSI/ITSDF B56.5 and ISO 3691-4 (confirm the current editions). Guard pinch points and moving parts, for example with a MISUMI extrusion protective guard.
Commonly Used Components for AGVs and AMRs
These warehouse automation component categories are commonly used in AGV and AMR builds.
Drive and motion transmission
Structure and framing
Mobility and material handling
Sensing, safety, and signaling
Tip: Prototype your chassis faster with the free FRAMES tool, check fit using 3D models from the inCAD Library, or get design help from RAPiD Design.
Use Cases by Industry
Moving pallets and unit loads between receiving, storage, and shipping.
Transporting orders to picking stations, packaging, and loading docks.
Delivering parts and finished goods between production lines and warehouses.
Carrying unit loads and components to line-side locations on repeatable routes.
Transporting supplies through busy corridors where AMRs must react to people.
Moving goods to packaging and pricing departments and shipping containers.
How to Choose Between an AGV and an AMR
Your route is stable and repeatable, and a fixed, guided path suits the job.
Build with: timing belts, rotary shafts, and E-stop switches.
Layouts change, traffic is mixed with people and forklifts, or you want to avoid expensive facility modifications.
Build with: aluminum extrusion, sensors, and stack lights.
You need a custom chassis, special payload fixtures, or a mix of vehicle types.
Build with: factory frames, bearings, and casters.
Frequently Asked Questions
An AGV (automatic guided vehicle) follows a fixed, guided route, using markers or wires in the floor or a combination of LiDAR sensors to establish routes and avoid obstacles. An AMR (autonomous mobile robot) self-navigates using mapping technology and onboard sensors, plans its own paths, and reacts to people and vehicles. The biggest difference is how each moves through a facility.
An AGV, or automatic guided vehicle, is a mobile robot that operates on a fixed, guided route and moves independently of an operator. Examples include driverless trains, pallet trucks, and unit load carriers. Depending on the type, it follows markers or wires in the floor or uses LiDAR (Light Detection and Ranging) sensors to establish routes and avoid obstacles.
An AMR, or autonomous mobile robot, is a robot designed to self-navigate and work collaboratively with humans. Onboard sensors and computers let it understand its environment and plan its own paths instead of following fixed routes. It uses LiDAR to recognize and react to people, cars, and forklifts, and it can even follow a person.
No expensive facility modifications are needed to automate a warehouse with AMRs, which makes implementation much simpler than with an AGV. Because AMRs navigate with mapping technology instead of fixed floor guidance, they also adapt more easily when operational needs change.
LiDAR (Light Detection and Ranging) sensors are the most common. AGVs use them to establish routes and avoid obstacles, and AMRs use them to recognize and react to people, cars, and forklifts. Vision systems and laser sensors are also built into these systems to help avoid accidents in and around the work environment.
The main benefits are increased workplace safety, faster order and delivery handling, better use of floor space, reduced warehouse logistics costs, more consistent quality from repeatable operation, a reduced physical burden on the workforce, and fewer shipment delays.
Common mechanical components include timing belts and pulleys, rotary and cantilever shafts, linear shafts, miniature linear guides, ball and roller bearings, factory frames, aluminum extrusion, rollers, slide rails, casters, and machined sheet metal. Common electrical components include sensors and switches, E-stop switches, stack lights, warning and signaling lights, and timers.
Up next in the series: the conclusion, Warehouse Automation Part 3: Automated Storage and Retrieval Systems (AS/RS). The benefits of warehouse robotics can take the load off the workforce and open new opportunities to expand your warehouse with MISUMI components.
Ready to build your AGV or AMR?
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