Automated Guided Vehicles (AGVs) for Aluminum Ingot & Coil Handling

Fori recently supplied three high capacity AGVs for the automated transport of aluminum ingots for aluminum coil production. 



  • Guidance Technology: Magnetic bar, inertial with pencil magnets
  • Capacity: 250,000 lbs./113,636 kg.
  • Safety: Safety scanners and bumpers, Siemens safety PLC, system interlocks
  • Controls: Siemens open architecture, vehicle management system
  • Keys to Success: Custom designed chassis, highly accurate and repeatable
  • Results: Improved flexibility, decreased crane usage

The (3) high capacity automated guided vehicles (AGVs) were supplied to replace a legacy system that was over 20 years old. The Fori AGVs will be the primary method of transporting the aluminum ingots through the finishing process. Traditional handling systems rely heavily on overhead crane utilization, but the AGV based solution reduces reliance on cranes.

The AGVs were designed to fit within the existing plant and process. One of the biggest challenges on the project was packaging eight drive wheels and (2) 100 ton capacity lifts within the existing vehicle footprint. Each drive wheel was outfitted with a suspension system to ensure proper radial loading and equal load distribution between the (8) drive wheels. Another improvement on the Fori system was ball screw based lift jacks that included integrated load cells for measuring fore/aft and side to side loading of the ingot. If the ingot is loaded outside of an acceptable range, the AGV stops immediately and sets down the ingot.


The Fori AGV utilizes a 72VDC sealed lead acid battery as a power supply.  The vehicles utilize PMAC motors that provide improved control and efficiency over the previous system which utilized DC brushed motors. Each vehicle had a safety bumper front and rear, as well as six safety scanners around the perimeter of the vehicle to provide added safety coverage.

A Fori Vehicle Management System has been provided to monitor system I/O, manage communication between the AGVs and scheduling of moves for production.

For more information about Fori Automation’s high capacity AGV capabilities, please visit our website.



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