ek robotics Revolutionizes AGV Control

Challenge

The engineers at ek robotics had initially developed a prototype using a conventional Raspberry Pi. The decision to use the Raspberry Pi was deliberate: Unlike classical control hardware, it offered an extremely powerful, versatile, and quickly implementable platform for an innovative development approach in the smallest form factor. For series production, ek robotics then needed a comparably powerful solution that would meet the requirements for industrial reliability, flexible application possibilities, and high control complexity. The system needed to:

Be industrial-grade and durable to ensure continuous operation in harsh environments
Combine edge computing, control, IoT gateway, and IPC functionalities in a single device
Feature a compact design to be installed inside the AGVs
Implement complex control tasks by enabling safe and efficient navigation and automated operations in various scenarios
Offer an attractive price-performance ratio

ek robotics is a globally leading manufacturer and system integrator of transport robotics for production and warehouse logistics. With over 300 employees across five locations in Germany, Italy, the Czech Republic, and Great Britain, the company develops intelligent, networked transport solutions for fully automated, internal material flow. Based on 60 years of expertise in the development and integration of Automated Guided Vehicles (AGVs), ek robotics supports its customers worldwide throughout the entire product lifecycle.

Solution

ek robotics chose to use the RevPi Connect as the central control unit for their AGVs. The system's flexibility and performance, combined with its modular architecture and attractive price, made Revolution Pi the ideal choice for series production.

Implementation

A safety controller ensures secure stopping and provides laser sensor data. The actual vehicle control, monitoring, and all communication are handled by the Revolution Pi and its I/O modules, which are used to control sensors and actuators and enable precise control logic. The modular expandability of Revolution Pi allows ek robotics to control any customer-specific attachments as needed. The Revolution Pi is securely mounted on a DIN rail in the vehicle, enabling its use under demanding operating conditions. For control programming, CODESYS and other specialized software solutions are used, handling tasks such as route optimization and fleet management.

Technologies Used:

RevPi Connect
Handles edge computing, control functions, and serves as IoT gateway.
SICK Safety Controller
Ensures obstacle detection and quick, automated stopping in case of danger.
Digital I/O Modules
Used for connecting various sensors and actuators to make the AGVs flexibly adaptable.
RevPi Con CAN Gateway
Enables CANopen communication with vehicle components.
CODESYS WebVisu HMI
Provides an intuitive user interface for operation and monitoring via the HDMI port.
USB Audio Adapter
Enables audio output for acoustic signals and notifications.

Results & Outlook

The use of Revolution Pi enables ek robotics to control their AGVs more efficiently and with space savings. The robust and reliable solution ensures trouble-free operation, even during extended use under demanding conditions.

A spokesperson from ek robotics confirms: "Revolution Pi offers us the ideal combination of high performance, flexibility, and cost efficiency." Thanks to Revolution Pi's modular architecture, the system can be further scaled and optimized through software updates in the future to meet the constantly growing requirements of the AGV industry.