Soft Design AB – The Interview

Soft Design AB is a leading Automated Guided Vehicle (AGV) supplier based in Gothenburg Sweden, with over 20 years’ experience in the AGV business. For many years Sweden has been thought of as the birthplace of modern AGV technology, with Volvo leading the way in the mid 1970s. AGVs are also known as Laser Guided Vehicles (LGV) or Self Guided Vehicles (SGV). Soft Design supplies AGV systems throughout Europe, either to major system integrators or direct to customers, delivering the high quality AGV manufacturing and software associated with Swedish suppliers. Soft Design’s European Sales Manager Tony Hughes spoke to Warehouse & Logistics News.

WLN – What do people say when they see AGVs at work for the first time?
AGVs at work are an amazing sight – anyone seeing them in action for the first time cannot fail to be mesmerised as these unmanned vehicles move around carrying pallets or products from A to B. AGVs are highly impressive and the perception is often of futuristic technology that can lift a company’s image, but it’s important not to lose sight of the fact that besides being technological marvels, they serve an important purpose. They work without breaks or holidays 24 hours a day, 7 days a week, 365 days a year, and while many companies have not considered implementing AGVs, thinking they may be too expensive for them, this is quite often not the case. Once a customer installs an AGV system, it is highly likely it will last for 20 years or more. We have recently replaced systems that have lasted for 20-25 years, so these installations have seen a great return on investment.

WLN – Why should companies invest in an AGV System?
There are many reasons. Most companies doing so have specific aims such as cost saving goals or a general improvement in terms of automation, but the main factors normally fall into two categories – increased utilisation and productivity.

AGVs can operate 24/7 without taking a break; they reduce time wasted waiting for late deliveries; there is less product damage; AGVs are controlled with incredible accuracy, +/- 3mm, so materials are always delivered to the right place, on time and in good condition; AGVs free up manpower from traditional transport systems; and finally, return on investment is typically 2-3 years, depending on the shift patterns.

WLN – How long has Soft Design worked with AGVs?
Soft Design has worked with AGV Systems as our core business for over 20 years, using our own unrivalled AGV Electronics (SONIX) and AGV Control System (MAX). About five years ago we made a huge investment in developing our products based on Microsoft platforms and standard AGV electro / mechanical components. This was a big change in direction for us, even if the goal and philosophy behind it was rather simple – we wanted to be able to change with the times much faster, but at the same time be able to support our existing customer base.

We now follow the Microsoft platform migration, which means when a customer wants to update his office or factory to a modern platform, our MAX system is ready for them and it’s just a simple case of upgrading MAX to the next generation. With our AGV electronics all versions are backward compatible, so when we develop a new SONIX platform it is a direct replacement for the older electronics.

Our AGV Hardware and the ease of its integration with other software systems is another of Soft Design’s strengths. Our roots as a software company give us an additional major advantage; we are able to offer complete turnkey AGV installations from the design, simulation and concept phases through to project installation, commissioning and customer support after handover.

WLN – Do you have standard AGV designs and products?
Soft Design and our electro-mechanical sister company Atab have together launched a new range of laser-guided AGVs that use AC motors and Sonix Electronics. The new range of AGVs includes the FX AGV (Forklift type) pallet handler, the CX AGV (Conveyor-loading) for warehouses, production facilities and the RX AGV (Reel handler) for the newspaper printing plants. We currently have 25 new Max generation systems running hundreds of AGVs, but historically our AGV designers have been involved in designing over 11,000 AGVs. These engineers have over 350 man years of experience between them.

WLN – What industries or sectors do you cover?
Soft Design is working successfully in all kinds of industries. For example, in the automotive industry we have entire car assembly systems using AGVs and engine assembly, Newsprint has also been an extremely successful sector for Soft Design in recent years – many of the UK’s leading daily newspapers use our AGVs to deliver two ton reels of paper to the printing presses. In the food and beverage sector, our AGVs transfer pallets from production to the warehouse, while another demanding, high specification area, is pharmaceuticals, where load tracking and traceability are needed at all times. Warehouse and distribution centres, as well as production and manufacturing sectors, are also traditional areas for our AGV systems. These are just a few of the sectors our AGV systems are running in.

WLN – What controls the AGVs?
Our AGV control system “MAX” is a state-of-the-art, dependable control system that runs on a modern client server Windows environment. It utilises Microsoft’s products and is easy to configure, and provides great possibilities for future expansion. It offers a user-friendly interface with well-presented screens and logical functionality that is easy to learn – anyone with a general interest in PC’s or who is a PC user can learn MAX. The visualisation comes with 2D and 3D alternatives, where operators can choose what is best for them. MAX controls the AGV routing, making last minute decisions along the AGV’s guidance path in order to select optimum routes to specific destinations. MAX also has a Warehouse module for keeping stock of inventory or buffer stock placed throughout the factory. MAX knows where these products are at all times, where and when loads come into the system or when they need to be dispatched or moved to other locations throughout the system.

WLN – How do AGVs know where to go?
This question is more for the technicians or engineers, but when it comes to the laser guidance system Soft Design uses a laser scanner from SICK that gives out the required X and Y coordinates. The laser is of the same power used in a standard CD player and very safe.

The laser scanner is mounted at a high position on the AGV, and the reflectors (targets) are strategically mounted on available landmarks like racking and walls, out of harm’s way so they are not easily damaged. The targets are made of high visibility reflective tape on a plastic cylinder, and a minimum of three targets must be detected at any time during travel. The targets can be located up to 30 metres from the AGV. The laser scanner measures the distance and angle to each target and gives out X and Y coordinates on a serial port direct to the SONIX AGV control unit.

AGV Systems containing more than one AGV require traffic control so the AGV’s do not run into each other. It’s a bit like having invisible traffic lights. MAX has no limits to the number of crossings or traffic-controlled intersections.

WLN – How do AGV’s pick up loads?
Load transfer is the pickup and delivery method for an AGV, which may be simple or integrated with other subsystems. For example, the AGV can be fitted with a roller bed or a chain conveyor; this transfers the load from one conveyor to another, anywhere within the factory. Traditional forks transfer pallets from floor to racking or racking to floor; the reel handler with movable v-shaped forks can handle large and small reels of paper. With AGVs for engine assembly or car assembly the load is carried on top or on fixtures. The load transfer possibilities really are endless.

WLN – Are there any limitations as to how large or small a system can be?
Soft Design offers solutions to meet our customers’ automation transportation requirements, from a single AGV to large integrated system solutions: there are no limits, large or small, to the amount of AGVs that MAX can handle. Load handling is also wide and ranges typically from 500kg to 5 tons. A MAX AGV system’s flexibility allows it to integrate easily with any industrial process or production and to communicate with all management systems (Ex: SAP, WMS, WCS, EDI, ERP, pre-delivery papinet).

WLN – What about training: do your customers have to be expert engineers?
Training is provided as standard for those members of the customer’s staff who will interact with the AGV System after installation and hand-over. Training will take place on-site or in Sweden. The AGV Control System and Maintenance training programmes will be geared to their level of expertise.

The numbers attending a training course are normally limited to a maximum of six people, to allow individual “hands-on” participation; of course, we will run more training courses to suit the numbers of staff for any particular system or multi-shift operation. We include a training programme for key personnel, who then can train subordinate staff on the AGV System’s operation and functionality. Depending on whether a system has one AGV or hundreds, training on the AGV system covers the following areas: general system appreciation, functionality of the system and equipment, supervisor training, systems training for IT technicians and the maintenance and servicing of the AGVs.

WLN – What about support for your customers after they buy an AGV System?
Providing customer care is extremely important, so we focus more and more on a partnership with our customers. This pro-active approach keeps our customers in touch with product changes and new developments; it also keeps us informed and updated with our customers’ requirements or changes to their needs for the AGV System.

Through many years of experience, Soft Design and our local service partners are able to design a service agreement that suits their needs. This ensures the most cost-effective maintenance plan and maximum up-time for our customers’ systems, leaving them to concentrate on their core business. Our service engineers are experts in the field of AGV maintenance and repair, and have in-depth product knowledge for fast fault finding and efficient repair.

Regarding spare parts, Soft Design holds a comprehensive stock of major components and during the warranty period all major components will be held on-site for two years. We are also able to guarantee spare parts delivery of stock held items from Sweden within 24 hours, anywhere in Europe. Software support and all AGV application software design and configuration are carried out in-house. This means tha­t software support is both fast and efficient, giving Soft Design an outstanding advantage when offering a 24/7 telephone or VPN support service.

WLN – What should a potential client do if they want to get more information?
Soft Design’s promise is to provide customers with the best priced AGV System, the latest innovative solutions and the highest level of customer satisfaction in the AGV market. Further information from Soft Design can be requested quickly and effectively by submitting an online request for more information, along with a basic outline of what is required. A technical support engineer will then contact you to discuss your requirements. Alternatively, just give us a call. Following your initial enquiry, a visit to site is always recommended. At a later date it will also be possible for a reference visit to one of our existing installations.

Soft Design AB
Tel: +46 (0)30035800
AGV@Softdesign.se
www.softdesign.se/agv