Wireless charging of AGVs and AMRs increases productivity

As a turnkey partner, the company – located in central Germany – provides bespoke production systems for customers in the automotive and aviation industries. As well as body shell production lines, FFT also implements automated maintenance concepts and manufacturing cells used in final product assembly. As part of its turnkey approach, FFT offers its customers a complete and coordinated solution, comprised of the production plant and all associated materials handling.  

To expand its range of services and meet customer demands for complete flexible automation solutions for the logistical interlinking of production plants, the company developed itsFFTigv automated guided vehicle (AGV) system. FFT’s customers expect a complete production environment from a single source that perfectly meets their requirements, which is why the company decided to produce an AGV system of its own. 

High charging power for large loads 

The FFTigv is fitted as standard with Wiferion by PULS charging technology. The tight cycle times in body shell construction and heavily staggered cycles were key drivers for choosing wireless charging as the power supply.  

FFT already has several thousand Wiferion by PULS etaLINK charging systems being used successfully so it was natural to use it in the new AGV system. The challenge was that because of the heavy goods being transported, the robots needed to be charged with high currents in just a short time. Wiferion by PULS therefore developed an energy system comprising high-performance batteries and chargers to meet the new requirements. The FFTigv has two etaLINK 3000 fast charging systems that, connected in parallel, produce a charging power of 6kW and supply the batteries with energy at a charging rate of 2C.  

In use around the clock 

The flexibility of the etaLINK fast charging system was crucial. The charging points can be positioned at almost any frequently used location in a warehouse either horizontally or vertically. Once a robot has moved alongside or over a charging point, the power transfer starts automatically, and charging is at full power after just a second.

In-process charging of the AGVs avoids having charging breaks and unproductive travel times to stationary charging stations, ensuring availability of the vehicles around the clock. This ensures the deployment of high-productivity manufacturing lines, as in the BMW Group factory in Leipzig. 

A further reason for FFT to select a WiferionetaLINKwireless charging system is its robustness. High-maintenance technologies are avoided and being encapsulated, the etaLINK does not use any mechanical components making it 100% maintenance-free. Worldwide, 130 etaLINK charging systems are in use in FFT’s AGVs and the company is currently developing a new manufacturing plant with a double-digit number of robots for the BMW Group’s Leipzig plant. 

Wiferion by PULS inductive battery charging systems enable the continuous operation of AGVs and AMRs. Their ‘in-process charging’ allows the vehicles to be supplied with energy efficientlyand fully automatically, without contact and without the vehicles having to interrupt their transport for charging breaks. 

This article originally appeared in the June'24 magazine issue of Electronic Specifier Design – see ES's Magazine Archives for more featured publications.