Automation in intralogistics has advanced rapidly in recent years, with more and more companies turning to autonomous mobile robots (AMRs) and driverless transport systems (AGVs) to boost efficiency. On paper, the potential benefits appear to be continuous availability, optimized material flow, and a significant reduction in manual labor. In practice, however, a critical aspect often goes overlooked: the energy supply.
“When businesses invest in automation, their main goal is to increase throughput. But many underestimate how much the charging strategy impacts the efficiency of their fleets,” explains Julian Seume, Director at Wiferion – a PULS business unit. “It’s not just about powering the robots. How they’re charged can determine whether the entire material flow runs smoothly and economically.”
Overlooked Costs: Downtime and Space
Conventional charging concepts typically require vehicles to move to dedicated charging zones for extended periods, causing idle times that are rarely factored into initial planning. This downtime poses a significant issue in high-demand environments such as e-commerce and production logistics, where even brief delays can disrupt the entire supply chain.
Another commonly underestimated cost factor is the physical space needed for charging. Every square meter used for a charging station is one that cannot be utilized for value-adding processes. “In many warehouse and production settings, space is a scarce commodity,” says Seume. “Companies need to decide whether they truly want to reserve precious floor area for charging—or whether there’s a better way.”
The Challenge of Mixed Fleets
Complexity grows when fleets comprise different robot brands, each requiring its own charging system. Installing separate infrastructures not only increases initial costs but also complicates fleet expansion, as every new vehicle may demand unique charging hardware.
Integrating Energy Supply into the Process
One strategy to maximize uptime is to integrate charging into routine operations—known as “in-process charging.” Rather than removing robots from service for lengthy periods, energy top-offs are administered in multiple short intervals, for example during brief pauses at transfer stations. This approach prevents unnecessary downtime and keeps vehicles constantly ready for use.
A study by MHP – A Porsche Company found that companies embracing optimized charging infrastructure can boost AMR or AGV fleet productivity by up to 50%. In addition, those that have successfully integrated process-based charging often see a reduced need for extra robots, since there is no requirement for backup vehicles during charging breaks.
Future-Proof Flexibility Through Standardization
Businesses eyeing fleet expansion should consider the benefits of a standardized charging infrastructure early on. “Many of our customers realized that their old charging system became a bottleneck once they tried to grow,” notes Seume. By selecting a cross-manufacturer charging solution, companies can seamlessly integrate new vehicles into existing operations, avoiding the high costs of multiple, incompatible systems.
When to Make the Switch
Organizations starting with a small AMR fleet often reach a point where inefficient charging processes can no longer be ignored—usually when the fleet is set to expand. A leading car manufacturer, for instance, discovered it could not feasibly increase its fleet size without overhauling its charging approach. By switching to an in-process charging concept, the company achieved a 30% increase in operating time per robot and reclaimed valuable space previously reserved for charging zones.
“There comes a time when companies must recognize that upgrading their charging infrastructure is not just a technical fix but a strategic business decision,” Seume points out.
Conclusion: Energy Supply as a Key Success Factor
Automating intralogistics aims to optimize processes and reduce costs. Yet without a thorough energy supply strategy, issues like downtime, space constraints, and costly infrastructure can undermine those gains. Businesses that opt for integrated charging systems benefit from maximum uptime, lower space requirements, and more flexibility in scaling AMR fleets.
“The right charging strategy isn’t just about technology,” concludes Seume. “It’s a crucial element in ensuring the economic viability of an automation project. Companies that plan for their energy needs from the start are far more likely to realize the full benefits of their AMR investments.”