AGVs (Automated Guided Vehicles) such as forklifts, unit load AGVs, or tuggers (tow tractors) became a game-changer in the fast-paced logistics industry, offering numerous benefits such as increased productivity, optimized workflows, improved safety, and reduced labor costs.
AGVs utilize various 3D camera technologies to enable autonomous operations, including obstacle detection, object localization, adaptive maneuvering, and real-time mapping.
Among these technologies, stereo depth cameras stand out as a cost-effective and technologically advanced choice, providing high imaging power and ensuring real-time, high-quality data.
Read about the advantages of stereo depth cameras for AGV systems, the challenges they must overcome to provide reliable vision systems for AGV and use cases from our clients.
The Advantages of Automated Guided Vehicles
AGVs play a crucial role in material handling and logistics operations, meeting the demands of today’s fast-paced supply chains.
Though the initial investment in the AGV fleet can be significant, the return on investment comes through multiple benefits:
- AGVs can work around the clock without breaks, significantly improving the efficiency of warehouse operations. That is particularly important in regions where there are not enough workers – AGVs provide long-term solutions at lower costs.
- AGVs equipped with sophisticated sensors and navigation systems can detect obstacles, avoid collisions, and follow predefined paths, minimizing the risk of accidents and injuries in busy warehouse environments. That also contributes to uninterrupted operations that successfully meet set goals.
- Automation allows the creation of AGV fleets, reducing operational costs, improving organization, and enabling faster delivery with fewer incidents. One person can easily operate an entire fleet, making the process more efficient and cost-effective.
- AGV vehicles collect valuable data, enabling businesses to analyze material flow, operational efficiency, and potential bottlenecks for process optimization.
Challenges in the Warehouse Environment and Technologies Enabling Forklift Autonomy
AGVs play a crucial role in material handling and logistics operations, meeting the demands of today’s fast-paced supply chains.
Their systems face challenges detecting static and moving objects while coordinating front, back, and side views to adjust real-time trajectories. Thus, high-quality images and fast, and reliable image transmission are critical as warehouse layouts may change frequently, requiring AGV vehicles to adapt their routes promptly for collision-free paths.
Automated AGVs use various technologies allowing them to see, understand, and react upon the inputs from their environments:
- Time of Flight (TOF): ToF sensors calculate distance by emitting infrared light. Measuring how long it takes for the signal to bounce off an object and return to the sensor, this technology acquires the whole scene in one shot.
- Stereo Vision: Using two image sensors at a known distance apart (known as the baseline), from the differences in the two images 3D information about the scene can be determined. This is the underlying technology used in the Framos D400e cameras.
- Structured light sensing technology projects a known pattern of light, often grids or lines, onto a surface. By analyzing the deformation of the pattern as it interacts with the surface, the system calculates depth and 3D information.
Each technology has its pros&cons, but in many cases, especially recently, stereo depth cameras are the first choice in many warehouse applications due to their combination of features, providing highly reliable and versatile solutions
Advantages of Stereo Depth Technology for AGVs Vision Systems
Stereo depth cameras found a way into many AGV applications, successfully overcoming all challenges of AGV vision and warehouse environment setting:
- Precise depth sensing capabilities enable AGVs to accurately perceive distances and understand the 3D structure of the environment and objects, providing the foundation of precise movement and materials handling.
- Real-time Mapping allows AGVs to adapt their routes on the fly and avoid collisions effectively. Creating and updating maps in real time enhances the AGV’s flexibility and responsiveness.
- Stereo depth cameras use visible light augmented by near-infrared patterns making them suitable for AGVs operating in complex and unpredictable warehouse settings.
- Compared to some other navigation methods, stereo depth cameras offer a cost-effective solution alongside high quality data and reliability.
- Integrating stereo depth cameras into AGV systems is simple compared to some other systems, which reduces development time and effort.
FRAMOS D400e Stereo Depth Cameras: Built to Withstand Warehouse Environment
Stereo cameras are an excellent choice for high-quality images and stable transmission, but a warehouse environment is not beneficial for stereo-depth camera sophisticated electronics and calibration.
Regular dust, debris, and water jet exposure can lead to malfunctions, image distortion, or permanent device damage.
Demanding conditions, including intense vibrations, cable stress, and frequent movements, necessitate industrial-grade connectivity solutions.
To address these challenges, we have developed the FRAMOS D400e.
This ruggedized gigabit Ethernet camera combines all the imaging features of the RealSense camera while offering additional protective elements to ensure flawless functioning and prevent premature end of life.
The key features of the FRAMOS D400e relevant for AGVs
- An IP66-rated ruggedized enclosure provides reliable protection against dust, water and physical impacts.
- Power over Ethernet (PoE) capabilities reduce cable clutter, improving the working conditions for both people and robots in the environment.
- The robust M12 and M8 plugs ensure secure and durable connections, making the camera suitable for deployment in the harshest and most demanding industrial settings.
- The FRAMOS D400e supports multi-camera setups, enabling better depth reconstruction. Multiple cameras can be networked using off-the-shelf Ethernet switches and routers, enhancing imaging capabilities.
- The camera’s compact design and mounting points on the backside make installation and mounting easy and convenient.
The FRAMOS D400e cameras maintain RealSense imaging quality while enhancing resistance to dust, water jets, and other challenging elements typical in industrial environments.
Use Cases for Stereo Depth Cameras
The versatility, easy implementation, reasonable pricing, and high-quality data of stereo camera make it applicable in various use cases.
Read two cases from our clients.
Retrofitting Robotic Tugs to Improve Greenhouse Productivity
Cyberworks Robotics is an innovative company developing fully autonomous vehicles for production environments.
For their client, Fernlea Flowers, one of the largest greenhouse operators in North America, they retrofitted existing vehicles in an AGV tractors fleet, improving workplace safety and order fulfillment efficiency.
Previously, Fernlea Flowers used an inductive strip taped to the floor, outlining paths for the tractors. The system lacked the flexibility to adjust to the ever-changing conditions within the environment dynamically.
To ensure autonomous drive and dynamic adjustment to the changing layout of the greenhouse and provide real-time detection of people and obstacles, Cyberworks Robotics used Intel® RealSense™ D435i depth camera.
Based on stereo depth camera input, the software assesses its surroundings to determine the best path through the greenhouse while avoiding any static and dynamic obstructions. Small size, cost-effectiveness, and high imaging power make stereo depth cameras an excellent solution for retrofitting fleets and developing systems from scratch.
Cyber Robotics solution allows an operator to remotely operate the 18 vehicle fleets, overcoming the shortage of workers, improving safety by preventing collisions, and fulfilling their orders faster and more efficiently.
For details of this case, please visit this link.
Using Stereo Depth Cameras to Develop Lifesaving Drivox System
Xesol Innovation is a global company specializing in “artificial vision” and deep learning for safer driving and road safety.
Having studied the problem of collisions and safety in an industrial environment, Xesol Innovation developed Drivox® Security.
This system accurately detects obstacles and gives drivers visual and auditive signs preventing collisions and accidents.
Drivox® Security by Xesol Innovation consists of three components:
- FRAMOS D435e cameras, fitted at the front and rear of the vehicle for three-dimensional perception,
- a microprocessor unit for AI-based image analysis
- a display serving as a monitor for the driver, which also shows the calculation results.
High-quality image and transmission reliability allow the system to discriminate between persons and objects and prioritize persons, significantly increasing workplace security.
The system provides a complete view of pedestrians and objects between 1.0 and 8.0 m from the forklift through a live stream at 30 fps with a 1280 x 720 pixels resolution.
To read a complete case study, please visit this link.
FRAMOS – Your Reliable Partner in AGV Vision Systems Development
Automated Guided Vehicles (AGVs) transform material handling and logistics through enhanced productivity, safety, and cost-efficiency.
Their autonomy depends on vision systems, which need to overcome challenges in recognizing objects, careful and precise handling of materials and creating reliable navigation software that detects static and moving objects in real-time while adapting to the everchanging layout of the warehouses.
On top of that, warehouse harsh environment demands robust protection for sensitive electronic components able to withstand daily exposure to impacts, debris, or dust.
Ruggedized gigabit Ethernet FRAMOS D400e camera with IP66 (optional IP67) protection safeguards sophisticated RealSense camera from dust, debris, and impacts, providing both high-quality image and industrial-grade robustness.
Gigabit Ethernet with Power over Ethernet (PoE) enables stable data transmission up to 100 meters (about 328.08 ft) through cables, while M12 and M8 plugs provide secure connectivity, reducing disruptions during AGV operations.
Last but not least, FRAMOS D400e cameras easily scale into multi-camera setups, allowing the assembly of surround view systems to improve the AGV’s situational awareness.
FRAMOS provides not only hardware – cameras and all necessary components – but also expert support for all optics and vision-based challenges throughout the AGV development process.
For more information about FRAMOS D400e cameras, please visit this link.
You can find the full scope of our product and services for AGV vision systems on this link.
