Continuous power supply or opportunity charging?

Driverless transport systems (AGVs) – also known as automated guided vehicles (AGVs) – are a core component of modern intralogistics and production automation. High-performance charging solutions for AGVs are a decisive factor in the availability, scalability and cost-effectiveness of automated material flows.

In many applications, AGVs now operate 24/7. Downtime due to empty batteries or charging problems can interrupt material flow and disrupt production processes. Therefore, the right energy supply plays a central role in the efficiency of automated transport processes.

Companies need an energy infrastructure that automates charging processes, minimises downtime and can be seamlessly integrated into existing fleet management and control systems. Choosing the right charging solution has a direct impact on OEE (Overall Equipment Effectiveness), TCO (Total Cost of Ownership) and long-term investment security.

There are two main approaches:

• In-motion charging (continuous energy supply)
• Opportunity charging (automated intermediate charging)

Both pursue the same goal: maximum availability with optimal energy supply. But which concept is suitable for which application?

Modern AGVs often perform transport tasks in continuous operation – for example, in manufacturing, intralogistics or distribution centres. This presents typical challenges:

• Unplanned downtime: If an AGV fails due to a lack of energy, this can interrupt entire production chains.
• Maintenance and wear: Classic plug-in or sliding contacts are subject to mechanical wear.
• Battery size and service life: Without intermediate charging, batteries must be larger, which increases weight, costs and wear.
• Complex charging planning: Operators must decide when and where vehicles should charge without creating bottlenecks in the material flow.

Modern charging systems for driverless transport systems therefore combine several technologies, such as lithium-ion batteries (e.g. LFP or LTO), intelligent battery management systems (BMS), automated charging algorithms, energy management and fleet control, and contactless or contact-based charging infrastructure.

There are basically two established charging solutions for AGVs: in-motion charging and opportunity charging.

The following criteria should be evaluated in order to make an informed choice of the optimal charging solution for AGVs:

• Required system availability (e.g. >99%)
• Route layout and structural infrastructure
• Number of vehicles and fleet dynamics
• Energy requirements and load profiles
• Environmental conditions (dust, humidity, etc.)
• Project duration and scaling strategy
• Integration capability into existing automation architecture

A holistic assessment includes investment and operating costs, life cycle costs, productivity gains and sustainability aspects such as energy efficiency and CO₂ reduction.

The choice of the right energy concept depends heavily on the requirements of the respective application.