AGV Produce Flexibly, Reliably and Sustainably for Automotive

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Diehl Energy Products GmbH

Beldrive Engineering GmbH

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

Beldrive and Diehl Energy Products have developed an AGV for one of Europe's largest automotive manufacturers, offering maximum flexibility, reliability, and sustainability in production. The project highlights how technological innovation and close partnership work together to meet the demands of modern industry.

The initial situation of the project was a challenge: the automotive manufacturer was looking for a solution to optimize intralogistics processes while preserving the existing infrastructure. Conventional transport systems, such as conveyor belts or energy supply and route detection via inductive floor lines, are often complex to install and limit flexibility. What was needed was a system that operates without fixed floor infrastructure, can be easily adapted to different production requirements, and ensures future-proof energy supply.

Durable Use

The Chemnitz (Germany)-based company Beldrive Engineering contributed its expertise in the development of modular vehicles that can be flexibly configured and adapted. The vehicles are designed to transport various loads and dimensions and can still be modernized or converted even after years. This system was complemented by the expertise of Diehl Energy Products from Röthenbach an der Pegnitz (Germany), who supplied a custom-developed lithium-ion battery. The batteries are characterized by their extraordinary longevity of up to 20 years—a significant advantage compared to the usual two to five years in the industry.

A particular highlight of the project was the development of an innovative battery management system (BMS). This system not only ensures maximum energy efficiency but also guarantees that the battery consumes minimal power in standby mode while remaining ready for use at all times. For the end user, this means that the battery does not sustain damage during extended idle periods, such as those that occur during seasonal production breaks. Thanks to a module integrated separately into the AGV, the system can be woken up from deep sleep mode and put into operation immediately without requiring manual intervention.

Coordination as a Success Factor

A key success factor was the close coordination between the two partners throughout the entire project. The combination of technological expertise and flexible collaboration made it possible to perfectly align the battery and the vehicle. This involved not only precisely implementing mechanical and electronic requirements but also making software adjustments to optimize energy management and enhance user-friendliness.

The battery-powered vehicles offer the significant advantage that no ground modifications, such as those required for inductive systems, are necessary. This allows production processes to be quickly and easily adjusted—a decisive benefit in times when flexibility in production is becoming increasingly important. The customer can deploy the system at new locations as needed, without requiring extensive structural measures. Additionally, the modular design of the vehicles ensures that future adjustments or expansions can be implemented without any issues.

Designed With Circular Economy in Mind

In addition to its technological advantages, the system also impresses with its sustainability. The long lifespan of the batteries reduces the need for spare parts and maintenance, while Diehl Energy Products' recycling concept ensures that the materials used can be reused at the end of their lifecycle. This allows both partners to set new standards in terms of resource conservation and environmental awareness.

For end users, the solution also delivers significant efficiency gains. Through CAN communication, the current state of the battery is monitored in real time, allowing potential issues to be detected early. This minimizes downtime and reduces maintenance effort. The capability for remote maintenance is another advantage, saving time and costs as many adjustments and optimizations can be performed without an on-site visit.

"This project impressively demonstrates what is possible through close partnership and mutual trust," emphasizes Thomas Wagner, Managing Director of Beldrive Engineering. "By combining our strengths, we were able to create a solution that not only meets current requirements but is also future-proof." Diehl Energy Products is equally proud of the collaboration: "Our battery technology was specifically developed for the high demands of the industry. The close coordination with Beldrive made it possible to create a system that sets new standards in terms of performance, safety, and sustainability," adds Rolf Pechloff, Product Manager and battery expert at Diehl Energy Products.

The project was not only a technological but also an economic success. The two companies plan to further expand their collaboration and develop similar solutions for other industries and markets. The close integration of experience and innovation is the key to sustainable growth and long-term success.

Everyone Benefits From Cooperation

The partnership between Beldrive and Diehl Energy Products highlights the importance of pooling competencies and exploring new pathways together. Through this collaboration, not only the involved companies benefit, but especially the customers who are equipped with a flexible, efficient, and future-proof system. This success story demonstrates that together, companies can not only overcome the challenges of Industry 4.0 but also actively shape its future.

* Simone Uhl is the owner of the agency Simone Uhl Marketing Inspiration.

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