ZF reduces manual transport trips through autonomous route trains

The automotive supplier ZF is using four autonomous tugger trains from 4am Robotics in its Passau-Patriching plant for the material supply of the assembly. According to the automation provider, the driverless vehicles transport approximately 430 shelf trucks and 260 small load carrier towers daily from goods receipt towards assembly. The solution is already in use in regular production operations and is intended to reduce manual transport trips and ensure the supply of the production areas.

Four route trains with four trailers each

Four autonomous route trains of the "ATi-M" series are used, each equipped with four trailers. The vehicles operate between the goods receipt and the assembly performance center. They independently navigate predetermined stops where the necessary materials are handed over.

The picking and provision of the load carriers continue to be carried out by employees in goods receipt. They prepare the shelf carts and small load carrier towers and load the trailers of the route trains. After starting, the vehicles independently determine their driving route. They continuously adjust speed and driving behavior to the respective environment and possible obstacles.

According to 4am Robotics, the solution is designed for demand-driven material supply to the assembly areas. The automated transports aim to relieve employees from manual trips and support the processes between goods receipt and production.

Navigation in Mixed Factory Traffic

A significant challenge in integrating autonomous tugger trains was the traffic conditions within the factory halls. The vehicles move during ongoing production operations on paths that are simultaneously used by pedestrians and manually operated vehicles like forklifts. Additionally, there are sometimes narrow traffic routes.

Therefore, the focus during implementation was on safe navigation, person recognition, and suitable braking and warning systems. Furthermore, the traffic management within the factory was regulated accordingly.

According to ZF, safety in the material flow has improved since the introduction of the autonomous tugger trains. This is due to the elimination of manual transport trips and clearer regulated intersection situations. Employees have also been specifically prepared to handle the driverless vehicles.

Real-Time Monitoring Shows Vehicle Positions

To monitor the transport processes, ZF uses a screen at the home station in the goods receiving area. This shows the current positions of the autonomous tugger trains in real time.

Employees can thus track where the vehicles are and when the next material delivery arrives at the assembly. This monitoring supports coordination between material provisioning, transport, and material reception in production.

During operation, the vehicles continuously transmit status information to the control center. These data also form the basis for communication with employees in the assembly area.