Why is the Demand for Heavy Load Transport robots (AGV) Growing?
Autonomous Transport Robots (AGVs) have been gaining significant attention across various industries. According to a report by global market research firm Research Nester, the AGV (Autonomous Guided Vehicles) market is estimated to be valued at approximately $5.2 billion in 2024 and is projected to exceed $30 billion by 2037.
As logistics automation rapidly expands, industries such as manufacturing and beyond are actively adopting these systems. Amid this trend, there is a growing demand for AGVs capable of handling not only lightweight cargo, as they traditionally have, but also increasingly larger and heavier loads.
Initially, AGVs were optimized for transporting relatively light materials. However, as industrial environments evolve, there is a rising need for automated systems capable of transporting large cargo weighing several tons or more.
The key drivers behind this shift include advancements in automation technology, changing industry requirements, and the growth of core technologies supporting these developments. In this article, we will explore why the demand for heavy-load AGV systems is increasing and examine the technological factors that make such advancements possible.
Technical Limitations and Future Developments of Autonomous Transport Robots
AGVs have traditionally operated by following predefined routes and performing designated tasks. They typically move along floor-installed guide wires or magnetic tapes, maintaining fixed paths. While this method allows for stable operation in relatively simple environments, it has the drawback of requiring a cumbersome process to establish new routes.
Recently, advancements in Autonomous Mobile Robot (AMR) technology have been addressing these limitations. Instead of merely following preassigned paths, modern AGVs are evolving to incorporate AI-based navigation systems and machine learning algorithms. These technologies enable real-time environmental analysis, allowing the robots to autonomously determine and adapt to optimal routes.
Notably, the integration of LiDAR sensors, camera-based object recognition, and SLAM (Simultaneous Localization and Mapping) technology has made it possible for AGVs to map their surroundings in real-time and dynamically adjust their paths.
Background of the Increasing Demand for Heavy Load Transport
The rising need for heavy-load transport is driven by the growing importance of automation systems across industries. As a result, there is an increasing demand for systems capable of reliably handling heavier loads. This trend is particularly evident in industries that require large-scale material handling, such as port logistics, manufacturing, and construction, where the adoption of AGVs is being actively considered.
A notable example in South Korea is Hyundai Rotem’s recent contract for an unmanned transport equipment project worth approximately 82.8 billion KRW at Gwangyang Port. This case suggests that the use of autonomous transport robots in port logistics is likely to expand in the future.
In the manufacturing sector, there is also a growing need for automated transport of heavy loads, such as large machinery components, automotive frames, and metal-processed products. Assembly lines often require precise placement of large components, and AGVs are emerging as a more efficient alternative to manually operated equipment for streamlining these processes.
Key Technological Elements for Autonomous Transport Robots in Heavy Load Handling
For AGVs designed to transport heavy loads, simply scaling up existing models is not sufficient. Autonomous transport robots for heavy cargo must be developed with multiple engineering considerations from the design phase, requiring various technological approaches to ensure optimal performance.
First and foremost, these robots must be structurally capable of withstanding substantial loads. This necessitates a highly rigid and stable frame design. Achieving this goes beyond merely using high-strength materials—it requires optimizing structural design to efficiently distribute weight and handle load-bearing stresses effectively.
Drive System with High-Torque Gear Reducers and Actuators
Ensuring an effective frame design for heavy-load AGVs or AMRs requires more than just structural reinforcement. The core drive components within these robots must also possess high durability and the ability to efficiently transmit powerful forces.
A high-torque gear reducer is a critical component that reduces motor speed while maintaining high torque output. For heavy-load transport robots, durable and high-reduction gear technology is essential. Among these, cycloidal gear reducers are particularly advantageous, as they provide superior torque transmission while maintaining a compact form factor. This makes them an ideal solution for AGVs, where internal space is often limited.
Additionally, as load capacity increases, maneuverability can become more challenging. To address this, differential drive systems and multi-axis steering mechanisms are often implemented. A differential drive system adjusts the speed of the left and right wheels independently, allowing smooth and stable turning without the need for separate steering components. In-wheel drive solutions are commonly used to integrate these capabilities effectively.
Application of a Slim Drive System for Structural Optimization
One of the key aspects of autonomous transport robot design is maintaining high durability and performance while minimizing overall size. In industrial environments where space is often limited, AGVs must be designed with a more compact drive system. To meet this demand, small high-torque gear reducers and slim actuators have recently gained attention.
Traditional multi-stage gear reducers and motors tend to be bulky, taking up significant internal space. This often complicates the component arrangement during the design process. To address this challenge, thinner yet stronger gear reducers must be implemented to maximize space efficiency while maintaining high torque output.
One of the solutions we have explored is the cycloidal gear reducer. Compared to conventional gear reducers, it offers superior structural robustness and a high reduction ratio, enabling the use of smaller gear systems while maintaining the same power output. This allows for more efficient use of internal space in AGV designs, improving both design flexibility and overall system efficiency.
Furthermore, the integration of motors, gear reducers, and control systems into a single unit—such as smart actuators—has become a key advancement in compact drive systems. This integration significantly enhances both space efficiency and overall performance.
When motors, gear reducers, and controllers are installed separately, unnecessary gaps and inefficiencies in layout are inevitable. However, by incorporating them into a single actuator unit, the installation process becomes simpler, space utilization is maximized, and maintenance is significantly easier.
Core Technologies for Heavy Load Transport: Gear Reducers and Actuators
To summarize, one of the most critical aspects of designing a heavy-load AGV is maintaining durability and performance while minimizing size. While traditional large-scale gear reducers and actuators provide excellent power output, their size and weight can compromise structural efficiency. For transport robots handling heavy loads, maintaining high torque while ensuring a compact design is a key challenge.
In AGV design for heavy load transport, the frame structure, drive system, gear reducer, and actuator must work in seamless integration to achieve peak performance. Among these, gear reducers and actuators are not just components but essential drive elements that enable high power output and precise control.
BSR Gear Reducer: High-Torque Cycloidal Technology
The BSR Gear Reducer is a high-torque cycloidal reducer designed to deliver powerful torque while maintaining a compact form factor. Compared to traditional gear-based reducers, BSR offers superior durability and impact resistance, ensuring stable operation even during continuous transportation of heavy loads.
These characteristics make BSR ideal for long-duration operations, providing high reliability in logistics warehouses, manufacturing, port operations, and other industries requiring heavy-load transport. [Explore BSR Series Products]
BCSA (Bonsystems Cycloidal Smart Actuator): Integrated Drive System
Seamless System Integration for Heavy Load AGVs
The BCSA is a fully integrated solution combining a motor, gear reducer, and control unit. Currently, the control unit is connector-type, allowing for partial drive functionality, but we are actively developing the next-generation fully integrated smart actuator (BCSA).
Designed to maximize structural flexibility, BCSA provides high torque output in a slim form factor, optimizing AGV space efficiency. As a modular unit, it simplifies installation and system integration, minimizing unnecessary space usage. [Explore BCSA Series Products]
For heavy-load AGVs, frame structure, wheel system, battery performance, gear reducers, and actuators must function cohesively to achieve optimal performance. Gear reducers and actuators are at the heart of autonomous transport robots, ensuring powerful output and precise control.
For product inquiries or technical integration support, please visit our product specifications page. Additionally, Bon Systems offers custom-made gear reducers and actuators tailored to client requirements. We also provide engineering support for specific industrial environments and technical demands.
For development inquiries or price quotes, please use the request form. For a detailed consultation, feel free to contact our team directly.
