Learn more about the systems that enable automatic guided vehicle systems to navigate as they maneuver loads safely through an operation.

There are five categories of automatic guided vehicles in the market. Learn the key differences when picking the best one for your application.

MODEX 2026 Session RecapAs autonomous mobile robots (AMRs) and automated guided vehicles (AGVs) become increasingly common in manufacturing, warehousing, and distribution environments, one component often receives less attention than it deserves: the wheel and caster systems that enable movement.During the MODEX 2026 session, "Efficient Casters and AGVs," industry experts explored the critical relationship between mobility components and automated vehicle performance. While software, sensors, navigation systems, and batteries often dominate automation discussions, the panel highlighted how caster and wheel selection directly impacts efficiency, battery life, throughput, maintenance requirements, and overall system reliability.The message was clear: automation performance starts at ground level.Every Pound of Force MattersFor AGVs and AMRs, efficiency is measured in more than speed. Energy consumption, battery runtime, and system longevity all play a role in determining operational success.One of the key themes discussed was rolling resistance—the force required to keep a wheel moving. Even small improvements in rolling efficiency can have a significant impact when multiplied across hundreds of vehicles operating thousands of hours per year.Reducing rolling resistance can help: Extend battery life Increase vehicle operating time between charges Reduce motor strain Improve throughput Lower total operating costsAs organizations seek greater productivity from their automation investments, optimizing wheel and caster performance becomes an increasingly valuable opportunity.The Floor and the Wheel Must Work TogetherThe session emphasized that AGV performance is heavily influenced by the interaction between the wheel and the facility floor.Factors such as: Floor condition Surface material Debris and contaminants Expansion joints Environmental conditionscan dramatically affect vehicle performance.Selecting the proper wheel material for the application is essential. A wheel that performs exceptionally well in one environment may create unnecessary resistance, wear, or vibration in another.Panelists stressed that successful AGV deployments require evaluating the entire mobility system rather than focusing solely on the vehicle itself.Reliability Drives ROIUnexpected downtime remains one of the most costly challenges facing automated operations.While organizations often focus on motors, controls, and software when troubleshooting AGV performance, mobility components can also contribute significantly to reliability issues.Wheel wear, bearing failures, flat spotting, and improper caster selection can lead to: Reduced efficiency Tracking issues Increased maintenance Unexpected downtime Higher operating costsDesigning mobility systems for durability and long service life helps ensure that AGVs deliver the return on investment organizations expect from automation technologies.Automation Requires PrecisionUnlike manually operated carts and equipment, AGVs rely on precise and repeatable movement.Even small variations in wheel performance can impact navigation accuracy, docking performance, and vehicle consistency.As AGV applications become more sophisticated, mobility systems must support increasingly demanding operational requirements. Precision bearings, high-quality wheel materials, and carefully engineered caster assemblies play an important role in helping automated systems achieve reliable performance.The panel highlighted that mobility components should be viewed as critical system elements rather than commodity parts.Sustainability Through EfficiencyAnother topic discussed was the growing focus on sustainability and energy consumption.Improving rolling efficiency not only reduces operating costs but also decreases overall energy demand. For facilities operating large fleets of AGVs, these gains can be substantial over time.Efficient mobility solutions contribute to sustainability goals by: Reducing energy consumption Extending battery life Lowering replacement frequency Minimizing maintenance requirements Reducing overall system wasteAs sustainability initiatives continue to influence capital investment decisions, mobility optimization is becoming an increasingly important consideration.Collaboration Drives InnovationA recurring theme throughout the discussion was the importance of collaboration between AGV manufacturers, mobility suppliers, end users, and industry organizations.No single component determines automation success. Instead, performance is achieved when all elements of the system work together.By bringing together expertise in automation, material handling, mobility, and operational requirements, the industry continues to develop solutions that improve efficiency, reliability, and productivity across a wide range of applications.Key TakeawayAs automation continues to transform material handling, the fundamentals of mobility remain as important as ever.The efficiency, reliability, and performance of AGVs depend on countless decisions made throughout the design process—including the wheels and casters that keep vehicles moving.The MODEX 2026 session "Efficient Casters and AGVs" reinforced an important lesson for the industry: when it comes to automation, smarter mobility drives better results.Organizations seeking to maximize the value of their AGV investments should look beyond software and sensors and recognize the critical role that efficient wheel and caster systems play in achieving long-term operational success.