AGV: heavy-duty automated guided carts

Description

Heavy-duty industrial AGVs for autonomous handling

CAPACITY: 0 – 1000 TONS

MORELLO designs and manufactures customized AGV carts for the autonomous handling of materials across the main manufacturing sectors.

Each automated guided vehicle is developed according to the characteristics of the load, the routes to be followed, the available space, and the plant’s automation logic. Morello specializes in the design of heavy-duty AGV solutions, with capacities ranging from 2 tons to over 1,000 tons.

The AGV system allows wheeled transporters to move materials fully autonomously, with no operator on board and without the need for physical guidance systems such as rails or fixed routes.

KEY ADVANTAGES OF MORELLO’S HEAVY-DUTY AGVs:

Lower operational costs
Enhanced workplace safety
Greater precision and higher productivity
Reduced risk of damage to products and infrastructure
Ability to operate in hazardous or explosive environments

Navigation technologies for AGV carts

MORELLO stands out among AGV manufacturers worldwide thanks to its wide range of advanced navigation technologies for automated material handling. The choice of technology (or combination of technologies) is defined together with the customer, based on operational needs, technical requirements, and budget constraints.

Below are the navigation systems available for our AGV carts.

Laser guidance

Laser guidance allows the vehicle to determine its position and move along defined routes with high precision. It is suitable for plants that require flexible routes and integration with advanced automation logic.

Inductive guidance

Inductive guidance is suitable for repetitive, clearly defined routes. The AGV follows a track embedded in the floor, ensuring continuity and reliability in cyclical handling operations.

Optical guidance

Optical guidance uses visual references to allow the vehicle to recognize and follow the route. It is an effective solution for applications that require orderly and easily reconfigurable flows.

Natural navigation

Natural navigation allows the AGV to orient itself using elements already present in the working environment, without requiring permanent physical guides. It is suitable for plants that require greater route adaptability.

Morello can also integrate magnetic, inertial, and dGPS guidance technologies, depending on the operating conditions and area of use.

INDUCTIVE GUIDANCE

OPTICAL GUIDANCE

INERTIAL GUIDANCE

LASER GUIDANCE

MAGNETIC GUIDANCE

dGPS GUIDANCE

Load types for heavy-duty AGV handling

Morello’s AGV transporters can be designed for different types of heavy industrial loads, including components, semi-finished products, machinery, coils, molds, steel products, precast elements, transformers and other oversized materials.

Each AGV cart is configured according to load capacity, dimensions, center of gravity, support requirements, lifting needs and the required handling cycle. When high maneuverability is needed, AGV solutions can also be developed with omnidirectional steering, drawing on Morello’s experience with OMNI multidirectional battery-powered trolleys.

Indoor and outdoor AGV operation: a distinctive asset

Not all AGVs are designed exclusively for indoor environments and regular floors. Morello manufactures industrial AGVs capable of operating both indoors and outdoors, including mixed routes between internal departments and external areas.

Each outdoor AGV project takes into account flooring, gradients, environmental conditions, required autonomy, wheel type, travel speed, and safety devices. Configurations are also available for offshore environments and areas with specific requirements.

Software integration and Industry 4.0

To ensure maximum customization and flexibility, MORELLO integrates both proprietary software developed in-house and industry-standard platforms from leading AGV software providers. This allows every aspect of the AGV cart to be tailored, from vehicle geometry to navigation paths and automation logic, fully aligning the system with the customer’s production workflow.

MORELLO’s solutions can include omnidirectional automated guided carts, systems capable of supporting multiple navigation technologies simultaneously, and AGVs designed to interface with WMS/ERP management systems, automated warehouses, and other machines within the plant.

This makes it possible to connect AGV handling systems with Industry 4.0 production environments, improving traceability, process control, safety management, and the efficiency of internal logistics.

ATEX-certified AGVs for explosion-risk environments

MORELLO is among the first companies in the world to design AGVs specifically for hazardous environments. Drawing on extensive expertise in ATEX applications, the company designs and manufactures automated guided vehicles compliant with ATEX Zone 2 requirements.

Integrating automation into explosion-proof AGV transporters helps reduce operator exposure in the most critical areas, increasing the safety of handling operations and improving overall workplace protection.

Technical characteristics


Capacity	from 1 ton to over 1000 tons
Dimensions	on request
Steering systems	front axle, all axles, ± 90° steering, omnidirectional	See the technology
Power supply	battery (electric grid or diesel generator on request)	See the technology
Travel speed	on request (from 1 km/h to 6 km/h)
Drive motors	AC motors (hydraulic motors on request)	See the technology
Steering motors	AC motors (hydraulic motors on request)	See the technology
Command	touch panel on board, notebook/s, pulpits, customer WMS/ERP
Navigation technologies	inductive, magnetic, laser, natural, dGPS, optical, inertial
Kind of wheels	solid rubber, polyurethane, pneumatic
Lifting deck	on request (lifting stroke from 50 mm)
Kind of battery	lead acid, gel, lithium, pure lead
Battery life	on request (from 1500 m to over 15000 m)
Climbing ability	on request (from 1% to over 20%)
Operating environment	indoor, outdoor, offshore
Safety devices	laser scanners, sensitive bumpers, ultrasonic sensors	See the technology
Industry 4.0 ready	yes	See the technology
Hazardous areas conform (EX)	on request (ATEX – only Zone 2)	See the technology