Automated Guided Vehicle for Automotive Chassis Decking Line

Fori recently provided a precision battery powered automotive Chassis Marriage AGV for an electric car manufacturer.


  • Guidance Technology: Magnetic tape
  • Capacity: 4,000 lbs./1,818 kg.
  • Safety: Scanners, bumpers, system interlocks
  • Controls: Allen Bradley Open Architecture
  • Keys to Success: Custom designed chassis, accurate and repeatable
  • Results: Increased flexibility, decreased infrastructure


The battery powered Chassis Marriage AGV includes dual independent lifters capable of lifting and transporting 4,000 pounds in order to install the front and rear suspension and drivetrain modules. This AGV was developed to support the end users lean automated manufacturing methodology. Not only will the AGV enable the end user to reduce their hardware investment, there will be significant flexibility in the assembly process. The guidance system of the AGV and reduced plant infrastructure allow the AGV to easily interact with other systems and processes. The AGV is outfitted with multiple safety measures that ensure collision avoidance.


The Chassis Marriage AGV is responsible for accurate and repeatable location of part in station for a reliable chassis marriage process. The AGV will provide increased flexibility, safety and decreased product damage, thus increasing profitability within the project for the end user.

For more information on Fori’s Chassis Marriage AGVs, please visit our website.


Automated Guided Vehicles (AGVs) — Tunnel AGVs

Fori recently designed and built a Tunnel AGV to support its global customers. The Tunnel AGVs are utilized for transporting product and dunnage throughout the production process.



  • Guidance Technology: Magnetic bar, inertial with pencil magnets
  • Capacity: 5,000 lbs./2,272 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

The Fori Tunnel AGVs are capable of automated docking and transport of carts up to 5,000 pounds. The Tunnel AGVs were developed to support the continued lean automated manufacturing methodology of the end user. The design intent was to build a vehicle that was modular and interchangeable.

In order to increase flexibility the Tunnel AGVs are capable of docking to various companion carts, each serving a unique purpose. Applications include pallet transfer, lift tables, powered trunnions and many others. Docking to the companion carts is completed with two docking pins. The docking pins ensure proper alignment to the companion cart for repeatable pick and drop.

The Tunnel AGV was designed to minimize the total footprint. With a height of 14 inches, the vehicle provides a high capacity material handling solution in a small footprint. The vehicle is comprised of two fixed drive wheels allowing for bi-directional travel and zero turn capability.


If required, a Fori Vehicle Management System (VMS) can be utilized for scheduling of vehicles and traffic management of the system. The vehicle controls are based on an open architecture utilizing a Siemens safety PLC, eliminating the dated black box technology that is commonly used. The Tunnel AGV has proven to be a cost effective and reliable material handling system for a variety of applications.

For more information on Fori’s automated material handling products, please visit our website.

Non-Automotive Assembly: Manual Vertical Conveyor System

Fori supplied manual push pallets on a vertical conveyor system consisting of a main build line and two vertical lift support stands.



  • Assembly Units Per Day: 500 units/2 shifts
  • Keys to Success: Operator ergonomics, flexible tooling, loop configuration, modular sections for line expansion
  • Results: Quality built assemblies, on time turnkey install

Fori took a powered vertical conveyor system and redesigned it to a manual push pallet system based on cycle times and cost requirements. The redesign provided the customer increased flexibility for their process. The line was designed in modular sections for future expansion of increased production or added processes.


The ability to be flexible with the pallet provided the ability to use the vertical conveyor for more than current parts or model changes. Overhead support for tooling was a jib boom that bolted to the floor to remove the assembly to dunnage.

The vertical conveyor system was integrated during the first quarter of 2017. The project was a great success for the customer and Fori Automation.

For more information about Fori’s assembly solutions, please visit our website.