Increasing Battery Life for AGVs, Tuggers, and Other Automated Systems

Less force to move AGV carts with ergonomic wheels means fewer injuries and longer battery life.

Adding industrial and ergonomic casters to automated systems in modern production facilities can look like a scene from a sci-fi movie. As robotic arms perform various functions, Automatic Guided Vehicles (AGVs) maneuver around the plant on their cart casters and wheels. All the while, automated conveyor systems move items around to all corners of these vast facilities.

The efficiency benefits of automated systems are a given. However, automation also consumes various resources, especially electric power. So much so that facility managers always seek ways to increase performance.? Increasing the battery life of AGVs, tuggers, and other machines that use a battery as their power source is a good start, especially when manufacturing plants can run production around the clock,? leaving little time for charging a battery.

Ways to increase battery life.

One way to improve battery performance on AGVs and battery-powered carts is to reduce the power needed to move the cart or the push force.

The harder it is to move a cart, the more power the motor must exert. This strain causes a greater demand for energy from the battery, reducing its life. Ergonomic AGV cart casters and wheels like the SoS Caster and TWERGO? wheels can significantly reduce the force needed to roll and maneuver. TWERGO? casters have been tested and validated (by ergonomic experts at Ergonauts Performance Technologies) to reduce push forces by over 55% compared to traditional casters.? This means less surface friction, which helps reduce the drain on batteries, extending the use time between charges.

Swivel on Swivel (SoS) on a TWERGO? Wheel

By placing a swivel section on top of a swivel section, we achieve a longer swivel lead than conventional casters. This design reduces the force required to rotate the caster and start rolling. The design also eliminates side-to-side shifting when the wheels rotate 180 degrees forward or backward in a straight line. These benefits all result in reduced operator fatigue.

TWERGO? Twin—and Triple-wheel designs have independently spinning wheels that can rotate in either direction and at any rate, minimizing friction when turning and maneuvering. These wheels are ideal for long Tug trains.

The effect is compounded on battery-powered Tug Vehicles that pull a train of carts. Using ergonomic casters and wheels on the train carts increases the Tugger’s battery life. This improvement can be exponential, depending on the number of carts. For manual material handling carts, reducing initial and continuous push force to reduce the risk of overexertion injuries has been a goal of engineers for years.

Maintenance to Prolong Battery Life

Another way to extend a battery’s life is not to overcharge it. Overcharging can damage the battery’s positive plate. A battery terminal protector should be added when a new battery is used. This helps protect battery life and reduces corrosion. It’s also worth scheduling time to clean your batteries regularly to prevent the build-up of dust and dirt, which can damage the batteries over time and reduce their lifespan.

Watch this video to know what are the benefits of having ergonomic casters on your AGV?

To learn more, visit our ergonomic products page or contact a solution specialist at 517-815-9299.