With the rapid development of robotics and artificial intelligence technologies, as well as the support of various favorable policies, the robotics and AGV industries are booming and being increasingly applied in production. Traditional manufacturing plants are gradually transforming into automated and digital factories.
AGVs can flexibly and efficiently complete material handling tasks. The improvement in production efficiency by using AGVs to replace manual labor is visible to the naked eye, which has won the favor of users. Various types of AGV vehicles and systems are constantly emerging in the market.
What is an AGV ?
AGV is an abbreviation for Automated Guided Vehicle , a type of ground-supported self-propelled vehicle powered by batteries. It travels along a predetermined path and stops at designated locations to perform a series of tasks. Depending on the method of material handling and the load, there are many types of AGVs , including common types such as lurking AGVs , towing AGVs , forklift AGVs , and mobile robots.
Different navigation methods, same protection requirements
Self-navigation is a key feature of AGVs. Through sensors on the vehicle body, it collects information about the surrounding environment and its own data to calculate its current position and guide its direction and path. Currently, widely used AGV navigation methods include magnetic strip navigation, QR code navigation, laser navigation, natural contour navigation, and visual navigation. Considering factors such as R&D difficulty, cost, path planning, flexibility, and ease of maintenance, different navigation methods have their own advantages and disadvantages.
Different navigation methods result in variations in the working capabilities of AGVs, but regardless of the form, the safety protection capabilities of personnel associated with AGVs are indispensable. Specific hazards associated with AGVs mainly arise from the automated movement of the vehicle, including:
Personnel remaining in the path of the AGV pose a risk of collision and crushing.
The danger of crushing in the trailer
Object falls
Unnecessarily blocking rescue routes or fire doors
Direct contact with electric shock (charging area), etc.
While well-designed Automated Guided Vehicles (AGVs) can interact with people more safely, improper use or maintenance can still lead to fatal injuries or significant property damage. A reported incident involved an AGV accident at a production plant of a globally renowned food brand, resulting in one death. The tragedy was attributed to a failure to adhere to relevant AGV safety standards.
It is evident that even with the most standardized and strict management, oversights are inevitable if appropriate protective measures are not taken as required. The only way to effectively reduce risks is to objectively improve the safety of the AGV itself.
Safety Standards Changes for AGVs
EN 1525 : 1998
EN1525 was the earliest AGV safety standard available for reference. However, some of its requirements are rather vague, such as ensuring adequate safety protection for the AGV and that the entire electrical circuit meets safety standards. Different AGV manufacturers interpret the standard differently, leading to inconsistent safety requirements across different companies. Furthermore, EN1525 's evaluation indicators are based on the EN954-1 standard's categories , which have long been superseded by EN ISO 13849-1 . Therefore, EN1525 is no longer entirely applicable.
EN ISO 3691-4 : 2020
The new standard EN ISO 3691-4 for AGVs , released in 2020 , updated the safety requirements. The new standard not only added additional functional requirements but also provided more detailed scenario classifications and specific quantitative requirements for the assessment dimensions. For safety level ( PL level) requirements, EN ISO 13849-1 is used to handle the safety-related parts (SRP/CS) of the control system .
Pilz is highly familiar with AGV industry standards and offers complete solutions that meet the Performance Level requirements for relevant safety functions in EN ISO 3691-4 , with highly flexible applications. For example, in terms of control functions, modular components can be used to evaluate signals from ordinary or safety encoders, monitor the vehicle's speed in real time, and switch the corresponding safety protection zone. Alternatively, signals from safety position switches can be used to determine the direction of the vehicle's drive wheels, thereby switching between left and right turn protection zones. Beyond safety protection, Pilz can also provide environmental measurement data directly for AGV navigation, preventing collisions, protecting goods and equipment, and reducing unnecessary system downtime.
The development of AGVs in China is currently very promising. Pilz's timely special feature aims to provide a comprehensive interpretation of the requirements of the EN ISO 3691-4 standard and corresponding solutions from a professional perspective, helping more companies understand how to produce AGVs that meet the standard requirements, and also helping more users to apply AGVs more safely .
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