Logistics
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Forklift-to-AGV Conversion

Converting existing reach truck fleet into autonomous AGVs without replacing equipment

AGV Jungheinrich WCS Navigation

Challenge

The facility has a fleet of warehouse reach trucks and seeks to automate logistics. Purchasing new AGVs requires significant investment and taking existing equipment out of service for extended periods.

  • High cost of turnkey AGV solutions
  • Taking existing equipment out of service for the full replacement period
  • Dependence on forklift operators β€” staffing shortages and shift coverage
  • Manual operation error risk and injuries

Solution

Phased conversion of existing reach trucks to AGVs. The first truck goes through a full R&D cycle, subsequent ones are converted using proven technology. Only one machine is out of service at any time.

  • Reverse engineering of forklift CAN bus for control electronics integration
  • Three types of localization available
  • SICK nanoScan3 safety system β€” safe operation alongside personnel
  • In-house Fleet Manager for fleet management and routing
  • WCS integration with warehouse management system

Key Advantages

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Investment preservation

Existing equipment is converted β€” no need to buy new AGVs.

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Phased transition

Only one machine out of service β€” production keeps running.

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Certified safety

SICK nanoScan3 ensures safe operation alongside people per ISO 3691-4.

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WCS + WMS integration

Integration with 1C, any WMS or ERP via REST API.

Technologies

  • SICK nanoScan3 safety scanner
  • Jungheinrich CAN bus reverse engineering
  • In-house Fleet Manager
  • REST API for 1C, WMS, ERP integration
  • Three types of localization available

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