Contemporary distribution centers operated by retailers, wholesalers, and manufacturers are turning to Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) in response to higher demand for faster, more scalable logistics. To meet this demand, a leading AGV OEM approached Bodine Electric for assistance in creating two customized gearmotors for their new vehicle: Since partnering, Bodine has manufactured, tested and shipped over 50,000 gearmotors for this customer.

The Challenge

There were a number of challenges in the needs of this project. The AGV required a single motor for lifting loads up to 1,000 lbs and large peak forces. What’s more, the AGV chassis was already locked down, so there wasn’t much room to fit in motors. The new devices would also have to operate round the clock for as long as five years in a harsh environment, enduring heavy shock and vibration and extreme temperatures.

The Result

In order to suitably address these needs, Bodine engineers designed all but the gearmotors virtually from the ground up:

• Small and low voltage BLDC motors combined with the best gearboxes for better battery life.
• Gearbox design that simplified the AGV’s final assembly.
• Custom made output drives to manage extra-duty conditions.
• Feedback devices built to follow the motor shaft accurately.
• A 1024 PPR encoder providing servo-feedback for precise motor control.
• Durable “military style” connectors and secure screw on connections provide high reliability.
• Performance monitoring and overheat preventing temperature sensors.
• A manual override feature to ensure operation even during power failures.

The result was two durable, high-speed gearmotors that have been used in AGVs everywhere. In addition to designing the gearmotors, Bodine assisted the OEM in navigating complex third-party approval protocols and helped ensure the products met regulatory and performance requirements. As a result of Bodine’s in-depth understanding of motion control, these vehicles now provide reliable day-to-day operation that makes warehouse work faster, safer and more productive.

Drawing on over 115 years of engineering development, Bodine Electric delivers custom solutions from packaging and medical equipment, to industrial automation and solar powered outdoor products. So if you need a custom or modified gearmotor, with Bodine you haven’t made things more complex – just intelligent.

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