To support the modernization of internal logistics within a production facility, Polytec Intralogistics carried out a complete revamping of two AGVs used for transporting metal bar bundles measuring 6 meters in length and weighing up to 6,000 kg. While the vehicles were structurally sound, their electronic and electromechanical systems had become outdated.

Following a thorough technical analysis, the decision was made to revise and upgrade the existing AGVs as a more cost-effective alternative to purchasing new ones. The project involved the complete replacement of onboard electronics, sensors, and actuators, while retaining the original drive wheels and structural frame, which were still in excellent condition. The top module was entirely redesigned to improve ergonomics and functionality, and a collection tray for oil and debris was added to reduce environmental contamination and protect vehicle components.

Operationally, the AGVs are loaded with bar bundles via overhead crane. Once the destination is assigned by the system, the vehicle moves autonomously to the unloading point, where the operator removes the load using the same crane. For non-standard loads, manual control is available via Teach Pendant, offering maximum operational flexibility.

Thanks to this revamping project, the facility was able to continue production safely, relying on renewed, reliable, and efficient vehicles. The solution provided clear economic advantages and extended the service life of the equipment—proving once again the value of revamping as a smart and sustainable choice.