Internal cart and trailer movements can be automated without fixed infrastructure by using an electric tug or tow tug that uses Natural Feature Navigation; these are known as Automated Guided Vehicles (AGVs). The machines use laser scanners to map permanent features such as walls and pillars, then follow programmed routes so there are no floor or site infrastructure changes required for navigation.
There are three main options for automating cart and trailer movement: manual electric tugs, semi-automated tugs, and fully automated AGVs. Each differs in how much floor infrastructure is needed and how involved operators need to be in the process. Pedestrian-operated electric tugs and Natural Feature Navigation AGVs are the only solutions that don't require changes to flooring or infrastructure.
MasterMover engineer machines at every point on this spectrum, meaning you can start with the option that fits your budget and processes, then scale your level of autonomy as operations grow.
Traditional AGVs need something physical on or in the floor to tell them where to go. That could be magnetic tape, painted lines, inductive wire cut into flooring, or reflectors and markers mounted around the site. However, this type of infrastructure often comes with trade-offs.
For operations that change often, such as contract logistics or lean manufacturing environments, these constraints can erode the return on an automation project.
Automating cart and trailer movement doesn't need to be a single overhaul project of your entire workflow. Solutions are on a spectrum and the right control option for your application depends on how often you move loads and how consistent your routes or floor layout are.
A pedestrian electric tug is the simplest way to eliminate strenuous pushing and pulling for your team; it is a battery-powered machine that couples to a cart, trolley, trailer, or equipment and takes all of the strain – needing no floor markings, route mapping, site layout changes, or operator certification.
MasterMover offers two manual control methods:
Manchester Airport Group's Motor Transport team recently boosted productivity by 200% after introducing a pedestrian TOW300 electric tug to handle baggage trailer movement.
Varied, low-to-medium frequency moves; sites starting their journey to automation; any move where an operator is already involved in the process.
A semi-automated tow tug handles steering on a repeat route while a person stays in the loop. It suits warehouses and plants that run the same point-to-point movements multiple times throughout a shift but are not ready to make the switch to full automation.
MasterMover's semi-automated option is Wireless AutoSteer, available on MasterTow ES and MasterHandler ES models. The tug follows a floor-mounted line for direction whilst an operator controls the speed via a remote, allowing for clear line of sight and precision manoeuvring during movements whilst maintaining an element of control for accurate and repeatable routes.
AutoSteer options do require a simple line on the floor; this is a light-touch install compared with cut-in wire but a fixed route nonetheless. If your goal is zero floor modification, go straight to Step 3 below or use remote control options until you are ready for fully autonomous solutions.
At this stage, it is also worth exploring multi-machine control. Our patented TillerLink and MultiLink allow one person to operate up to four synchronised electric tuggers at once for even more weight-moving capacity, removing the need for extra crew on long or awkward loads with no floor infrastructure required.
A leading space technology manufacturer implemented semi-automated PS3000+ machines with both Line Follow and MultiLink technology to move 50,000kg satellites through tight production areas with millimetre accuracy, eliminating the risk of costly damage to loads during movement.
High-precision, repeat moves on consistent routes; sites that want a first step towards automation; teams that want an operator to remain in control.
Fully automated AGV electric tugs use Natural Feature Navigation to automate cart and trailer movement with minimal infrastructure changes, as navigation is based on your existing building and layout – the direct solution for teams that are looking for fully automated material handling processes without having to make large-scale site changes.
MasterMover AGVs are ideal for:
As there is nothing on the floor to follow, a Natural Feature AGV is not limited to one building. In open outdoor spaces, with no permanent features to reference, MasterMover AGVs use high-precision GNSS for centimetre accuracy at all times – even outdoors. Our outdoor AGVs are able to continue load-moving routes whilst transitioning between buildings, travelling over slopes, and operating in rainy conditions.
Route actions can also communicate with site PLCs to control shutter doors and traffic lights. Toyota uses MasterMover AGVs to automate the movement of resin back doors through its assembly plant whilst operating alongside other vehicles.
High-frequency, repeatable movement in dynamic layouts; multi-shift operations; routes that transition between buildings where floor guidance isn’t possible.
The right degree of automation for you is dependent on how often loads are being moved, how consistent the routes are, and the level of infrastructure adaptations your site can accommodate . These four questions help to narrow down a suitable solution for your site.
How often is the load being moved?
A few times a day would point to pedestrian or remote control electric tugs; whilst automation would pay back fastest for load movements that happen dozens of times per shift and across multiple shifts.
Looking at return on investment, MasterMover AGVs can reach 50% to 150% ROI on a single shift over three years, rising to over 600% across three shifts over five years.
These returns come from automating the right processes. Start by listing the cart and trailer moves your site makes in a typical shift: how often each happens and how many staff are tied up in the process. Frequent, repeatable handling processes are usually where an AGV pays back fastest, while varied or occasional moves tend to be better served by a pedestrian or remote control electric tug.
Here at MasterMover, we cover the whole control technology spectrum so you can rest assured our expert team will specify the right solution for you, that delivers the results you need.