More and more companies are leaving internal transportation tasks to driverless transport systems (AGVs) or automated guided vehicles (AGVs). Long downtimes are unacceptable, and having alternatives available for emergencies would negate the benefits of automation and is often not even possible. AGVs therefore need high availability and reliability.

"One key to long-term high reliability values is the use of high-quality materials, combined with mechanical designs that can cope with the challenges of everyday operation, such as uneven ground," explains Martin Lindner, CEO of the independent Austrian AGV manufacturer Melkus Mechatronic. "Another is the consistently modular design of the vehicles, as this simplifies and accelerates maintenance, repairs and subsequent adjustments, thus ensuring short downtimes." Melkus has therefore opted for a completely modular AGV design.

Maintenance and spare parts inventory

All key components of the AGV from Melkus Mechatronik are designed as self-contained, industrial-grade modules. Many of them are installed in all of the manufacturer's vehicles. This applies not only to the industrial-grade drive unit, the Melkus turntable, which enables omnidirectional driving in all Melkus vehicles. It also applies to the lifting unit, the traction battery, the control unit and the sensors, as well as the vehicle software. Like most chassis parts, all mechatronic modules can be replaced quickly and without special tools on site after brief training by customer personnel, according to the supplier. In addition, the modular design with a high proportion of identical parts, together with the identical design of both skids, significantly reduces the cost of stocking spare parts for driverless trucks.

In addition to easy maintenance, modularity is the key to long-term investment security. It enables quick, even subsequent adaptation to individual customer requirements, such as load handling devices or attachments. This applies in particular to the central control hardware. This is not a small-series special development, but a modular industrial control system from Sigmatek that has proven itself in industrial applications. Consisting of stackable modules for CPU, safety and input/output modules, this enables fast module replacement in the event of a fault, as well as the integration of new technologies, such as additional sensors.

Self-developed on-board software

The on-board software, which was developed entirely in-house, is also completely modular thanks to object-oriented programming. Connecting and configuring standardized object classes simplifies and accelerates the creation of the target software for the individual vehicle and also facilitates troubleshooting, software maintenance and continuous improvement as well as testing and commissioning. As part of its approach, Melkus uses open standards such as the VDA 5050 interface to connect to any control system, regardless of its manufacturer.

"Customers value practical systems with maximum availability," concludes Martin Lindner. "This is exactly where our modular approach comes in. We deliver maximum efficiency with minimum downtime."