Polytec Intralogistics has developed an advanced automated intralogistics solution for a major industrial customer in the automotive sector. The system is designed to enhance production flow efficiency and reduce manual handling of heavy materials within the facility.

At the heart of the system are 5 autonomous guided vehicles Voyager 50, engineered to safely transport stacks of trays weighing up to 750 kg and measuring 890 x 890 mm. Each vehicle is equipped with a custom-designed top lift, for the automatic loading and unloading of trays within the various workstations of the plant.

Both in-process and finished products are automatically conveyed to a vertical automated warehouse capable of housing up to 250 trays. Storage and retrieval operations are handled by a trilateral AGV with a load capacity of 1,000 kg and a maximum operating height of 6 meters, able to function with high precision in narrow aisle environments.

The system ensures complete flow management through a Warehouse Management System (WMS), which manages all AGV missions, monitors material status in real-time, and communicates bidirectionally with the MES, robotic work cells, and other machinery within the facility.

The WMS centrally manages the entire production layout, coordinating the flow of trays between workstations and the warehouse. This ensures operational continuity, reduced handling times, and complete traceability of each load unit.

The current installation includes 5 AGVs Voyager 50 and 1 trilateral AGV, but the overall project envisions an expansion to 15 AGVs Voyager 50 and 2 trilateral AGVs, demonstrating the scalability of the solution and the strategic value of automation in the customer’s production site.

Today, the system operates autonomously, drastically reducing manual labor and ensuring smooth internal flows, with a high level of integration and control that enhances the overall efficiency of the entire facility.