Intralogistik
Robots in logistics: is the route profitable?
In practice, robotic logistics means throughput. In intralogistics, it's not a product characteristic that determines success, but a simple calculation. Three figures tell you whether a route can be automated and how many machines are needed.
This page calculates the calculations, with disclosed assumptions. It then addresses the point where most calculations fail, the conditions in the hall, and the models we use for freight transport.
- The three numbers that will decide the case
- Calculation example: one route, three scenarios
- Where the equation flips: the handover
- AMR or driverless transport system
- What tasks do robots perform in logistics?
- Models for freight transport
- Conditions in the hall
- Warehouse and office: the shorter routes
- Frequently asked questions
The three numbers that will decide the case
A logistics robot doesn't replace a machine; it replaces travel time. The throughput of a route is therefore the key metric, not the speed of the device. Whether it's profitable depends on three factors, and only these three. Everything else is just a detail.
Trips per day
How often does the route actually need to be served? Not how often it would theoretically be possible, but how often the demand arises.
Driving time per lap
There and back, at a realistic speed rather than the data sheet value. People in the way, curves, and doors cost time.
handover time
Loaded at the start, unloaded at the finish. The task that almost everyone underestimates and that ultimately determines the number of devices.
Lap time = round-trip travel time plus handover at the start plus handover at the finish. Usable laps per day = operating time divided by lap time, minus buffer for charging and malfunctions. Devices = required trips divided by usable laps, rounded up.
Calculation example: one route, three scenarios
The following is a model calculation with disclosed assumptions, not customer data. It shows the strength of each lever.
assumptions
Distance 180 meters one way, so 360 meters per lap. Effective speed 1,0 meter per second, so 6 minutes travel time per lap. Operating time 8 hours, which is 480 minutes. Buffer 15 percent for charging, maintenance, and malfunctions. 60 trips per day are required.
The effective speed is deliberately set below the data sheet value. Curves, doorways, and evasive maneuvers take time.
| scenario | lap | Usable rounds | Devices for 60 trips |
|---|---|---|---|
| A: Handover 2 plus 2 minutes | 10 Minutes | 40 | 2 |
| B: Handover 5 plus 5 minutes | 16 Minutes | 25 | 3 |
| C: Route halved, handover 2 plus 2 minutes | 7 Minutes | 58 | 2 |
The teaching is in rows B and C. Six minutes of additional handover time costs 15 usable laps. Halving the distance yields 18 laps. Both levers are almost equally strong , but only one can be changed without modifying the hall.
This is precisely where the misconception lies in many inquiries. The question is about the faster robot. The real winner is the handover process.
Limit of this calculation
The model calculation indicates how many devices are needed for a given route. It says nothing about whether the investment will pay off. For that, you need the actual personnel costs for current travel times, and only the company itself knows those.
Where the equation flips: the handover
A robot waiting for personnel is an expensive undertaking. The handover process determines whether automation becomes profitable, and it has three development stages.
Level 1
Manual handover at both ends
Someone loads, someone unloads. The robot simply handles the transport. This is the simplest starting point and works wherever the transfer is already part of an existing work step.
It tips over if no one is waiting at the finish line. Then the device stops and the lap time skyrockets.
Level 2
Swap wagons instead of reloading
The robot drives under a roll container, lifts it, and moves it away. At the destination, it sets down and picks up the empty cart. Unloading is completely eliminated, reducing the handover time to under a minute.
It requires standardized vehicles and defined parking spaces. That's often where the problem lies, not the technology itself.
Level 3
Fixed transfer station
A station picks up the load and delivers it without anyone needing to be present. The robot operates around the clock. This is the most expensive option and the only one that allows for true night-time operation.
It only becomes cost-effective at high frequencies. Before that, level 2 is the better compromise.
AMR or driverless transport system
An autonomous mobile robot, or AMR for short, navigates freely. It knows a map of the hall, plans its own route, and avoids obstacles. A classic driverless transport system, or AGV for short, follows a fixed track, formerly a wire in the floor, now usually magnetic tape or reflectors.
The choice hinges on the stability of the layout. If the hall changes its parking positions several times a year, free navigation is advantageous because a new route is a software change, not a manual operation. If the same line always runs at the same frequency, track guidance may suffice and is more robust against disruptions during operation.
The second difference is mixed traffic. Where forklifts, pallet trucks, and people share the same space, the vehicle must be able to maneuver around them. A fixed lane doesn't allow for this. A detailed comparison can be found on the AMR vs. AGV page.
What tasks do robots perform in logistics?
Not every route in the warehouse is suitable for automation. These four almost always are, because they are predictable, recurring, and labor-intensive.
| Task | Why it's worth it | load class |
|---|---|---|
| Goods receipt to the storage area | Fixed start and finish zones, high frequency, clearly plannoticed | pallet or wire mesh container |
| Picking zone for shipping | Recurring route, often the bottleneck at the end of the day | Roll container or bin |
| Production to interim storage | Clocked demand and travel time keep skilled workers away from the machine. | pallet or trolley |
| Return empty containers and packaging material | It's running in the background today and therefore won't be played. | trolley or wire mesh box |
What's not included: gripping, order picking, packing, labeling. A logistics robot transports. Anything that requires hands remains with humans or requires a separate system.
Models for freight transport
For logistics routes, the relevant equipment is the lifting device and the heavy-duty platform. Tray robots from the catering industry are irrelevant here.
| Model | load class | Typical use |
|---|---|---|
| AutoXing FT2000 Pallet Truck | Pallets and heavy loads, 2.000 kg according to internal specifications | Goods receipt, production, intermediate storage |
| AutoXing FT1500 Pallet Truck | Pallets and heavy loads | As above, smaller load class |
| AutoXing AX8112 L-150, L-300, L-300E | Roll containers and trolleys | Picking zone, shipping, material transport |
| AutoXing AX8113 L-600 | Larger cars, higher frequency | Multi-shift operation, longer distances |
| AutoXing AX8114 S-150, S-300, S-300E | Roll container, sub-lifting | Drive under the car, narrow streets |
| AutoXing AX8113 S-600 | Heavy vehicles, sub-lifting | Production, intermediate storage |
| T300 with lifting, T600 underride | Roll containers on a compact route | Narrow corridors, smaller halls |
| AutoXing AX6113 D-150, D-300 | Containers and boxes | Small parts, tools, mail delivery within the company |
How this list is created
The models are taken from our catalog, not from a comparison article. We will provide the load capacity and weight from the specific model's data sheet once the route is finalized. Prices belong in the quotation because they are determined more by the number of units, charging points, and transfer stage than by the unit itself.
If the issue isn't about loads in the hall, but rather about routes within the building, then the transport robots section is the appropriate place to look. There you'll find route planning that takes into account door widths, thresholds, and elevators.
Conditions in the hall
Unlike in office buildings, door widths are rarely the problem. Five other points are.
Point 1
Floor and joints
Industrial floors are generally unproblematic, but expansion joints and manhole covers are not. For heavy loads, the load-bearing capacity of the floor is also a crucial factor, especially on mezzanines and ramps.
To be checked: joint widths, covers and grates along the route, load-bearing capacity for loads over one ton.
Point 2
Aisle width and turning areas
A heavy-duty platform needs space to turn around, even when loaded. The turning circle is the point at which hall layouts need to be adjusted, not the driving width.
To be measured: aisle width, free space at each parking space, distance to shelves and columns.
Point 3
Mixed traffic with forklifts
This is the crucial safety point. Forklifts have priority, intersections with obstructed views are critical, and the route should ideally cross forklift paths rather than follow them. Where this isn't possible, separate time slots or physical separation are necessary.
To be clarified: forklift routes, intersections, visibility conditions, whether separate driving lanes are possible.
Point 4
Radio coverage across the entire route
Warehouses with metal shelving have dead zones for mobile data. This is tolerable for the journey itself, but not for status updates and remote access. A dead zone in the middle of the route will later be reported as a fault.
To be measured: Signal strength along the route, especially in aisles and at gates.
Point 5
Charging stations and shift work
For a single device, a charging point at the edge is sufficient. With three devices operating in two shifts, charging planning becomes part of the round-robin calculation, because charging time is deducted from operating time.
To be clarified: number of charging points, locations outside of traffic routes, power connection, fire safety approval.
Warehouse and office: the shorter routes
Not every logistics route leads through a warehouse. In administrative buildings with an attached warehouse, the routes are shorter, the loads smaller, and the frequency lower. Mail, consumables, small parts, file relocations.
The calculation is the same, just with different figures. With twenty trips per day and short distances, one device suffices, and the handover can even remain manual because the frequency doesn't make it a bottleneck. However, issues related to the building itself come into play: doors, elevators, and corridor traffic. These are all geared towards transport robots.
The most common issue at this scale is not efficiency, but relief. If a person spends two hours a day carrying materials around the house, it's not a question of cost, but rather a question of what else they could be doing during those two hours.
Frequently asked questions
What does a robot do in logistics?
It moves loads on recurring routes within a location, i.e., intralogistics.
Typical processes include goods receiving to storage location, picking zone to shipping, production to intermediate storage, and empty containers returned. Retrieving and picking are not part of this process.
How many robots do I need?
Number of trips required per day divided by usable rounds per day, rounded up.
The number of usable laps is calculated by dividing operating time by lap time, minus buffers for charging and disruptions. Lap time includes travel time to and from the station plus both transfer points.
What is the difference between AMR and FTS?
An AMR navigates freely and avoids obstacles, while an FTS follows a fixed track.
Free navigation is advantageous in situations with changing layouts and mixed traffic. Lane guidance can be more robust on a consistently timed line.
How heavy can the load be?
From a few kilograms in the container up to 2.000 kg for the AutoXing FT2000 according to internal specifications.
The selection is based on the heaviest load on the route. For loads exceeding one ton, the load-bearing capacity of the ground is also tested separately.
Can robots and forklifts use the same space?
Yes, but that's the safety-relevant point and needs to be planned in advance.
Obstructed views at intersections are critical. Where paths cannot be separated, we work with separate time slots or physical separation.
How long does the introduction take?
The route is set up quickly. Time is needed for loading points, transfer points, and coordinating with forklift traffic.
Those who go to stage 2 of the handover process, i.e. exchanging wagons instead of reloading, also need standardized wagons and defined parking spaces.
Does it make financial sense?
The number of devices can be calculated in advance, but profitability cannot be determined without your figures.
This requires the actual personnel costs for today's travel time. We calculate this in consultation with you, using your specific figures, not industry averages.
Calculate the route
Tell us the route length, the number of trips per day, and what is being transported. We'll calculate the round trip time and the number of vehicles required, and tell you honestly if the frequency is too low for automation to be profitable.