Machine builders around the globe are pressured to get products to market faster as development delays reduce profitability and strain resources for innovation. Machine builder, AutoGuide LLC, based in Georgetown, Ky., felt this pressure as it sought to build an automated guided vehicle (AGV) conversion kit that could meet its customers' demands for simplicity and field support. They needed a wide range of components.

Serving industries such as automotive, medical supplies and cosmetics, AutoGuide automates plant-wide ground transportation of point-to-point material systems. Unlike manually driven vehicles, AGVs provide smooth, predictable flow of materials and products throughout a manufacturing facility to help streamline production.

"Statistically, AGVs are much safer than manually driven vehicles, because they eliminate human error and human attitude. AGV traffic is all pre-programmed and thought through, and implemented in a controlled manner," said Paul Perry, president and CEO of AutoGuide. "Until recently, converting standard industrial trucks and forklifts into state-of-the-art AGVs has been too daunting for some of our customers."

Challenge
Prior to working with Rockwell Automation, AutoGuide built an AGV by integrating controls directly into a vehicle. This rewiring of the original vehicle typically took AutoGuide two weeks to complete. While AGVs provide customers added safety, security and a solid return on investment, AutoGuide recognized that the time and money investment for a conversion was significant enough that several customers were hesitant to invest. In addition, customers were reluctant to rewire their vehicles' original controls out of concern that they would risk ease of serviceability.

"In this business, converting a vehicle intimidates people," said Perry. "But if the process was more adaptive and less intrusive, such as an add-on control kit instead of complex vehicle rewiring, we figured customers would be more willing to invest."

AutoGuide set a goal to develop a modular controls AGV kit that could attach to the vehicle, enabling customers to convert their vehicles to an AGV without having to rewire the vehicle. This new kit would include off-the-shelf components and incorporate its proven AGV technology into a cabinet designed as a bolt-on attachment. In addition, the kit would complement the vehicle's aesthetics, functionality and serviceability.

Solutions
AutoGuide turned to Rockwell Automation to build a solution that maximized the AGV kit's reliability and performance. A decade-long customer of Allen-Bradley^®, Perry wanted an automation partner with a full offering.

"We picked Rockwell Automation because it could provide everything we needed, including product reliability and support," said Perry. "Our first customer was very demanding when it came to component reliability and support; but once we said we were partnering with Rockwell Automation, they were right at ease."

Perry combined the complete offering from Rockwell Automation with product selection support to choose the right components for each application. Each kit is enclosed in a durable steel cabinet with easy service access, and features a convenient harness to plug into the truck wiring that eliminates traditional splicing or wiring alterations.

"We designed the kit with modular components that include quick disconnects for most products, so if something goes wrong on the vehicle motor or transmission, users can dismantle the kit in an intuitive, modular fashion, or they can easily remove the whole kit and get total access to the vehicle," said Perry. After performing the required maintenance, users bolt the kit back on, and the vehicle is up and running.

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