This article includes everything you need to know about autonomous mobile robots and their use.
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An autonomous mobile robot, or AMR, is a self-powered and self-propelling device engineered to execute repetitive tasks and organizational functions using its internal guidance system. These robots traverse their environments with the aid of advanced mapping and software technologies that enable them to "SEE" and comprehend their surroundings to perform a wide range of tasks. With the integration of sensors, artificial intelligence, machine learning, and computer algorithms, AMRs can effectively recognize obstacles and avoid collisions.
AMRs are equipped with sensors that continuously monitor their surroundings to identify possible hazards or obstacles. When such issues are detected, the AMR autonomously computes and follows an efficient route to bypass them. During their initial deployment, AMRs are furnished with mapping technologies like visual simultaneous localization and mapping (SLAM), facilitating real-time navigation decisions based on environmental observations.
AMRs are frequently described as having the capability to "SEE" their surroundings due to their utilization of light detection and ranging (LiDAR) technology. LiDAR uses pulsed laser sensors to ascertain distances, providing AMRs with a comprehensive understanding of both their position and the objects around them. Serving as the "eyes" of an AMR, this technology is crucial for accurate navigation and interaction within various environments.
To meet the rapidly growing demands of modern distribution and warehouse operations, the order fulfillment and logistics industry has increasingly turned to advanced automation and robotics solutions. Traditional material handling methods, such as manual picking, pallet jacks, and operator-driven forklifts, lack the speed, efficiency, and scalability required to keep up with e-commerce and omnichannel retail trends. As a result, warehouse automation has evolved through the adoption of smarter, more versatile computer-programmed robotic technologies to improve throughput, accuracy, and cost-effectiveness.
Initially, automated guided vehicles (AGVs) were introduced to support industrial automation and address material transport needs. These vehicles follow predefined paths marked by tape, wires, reflectors, or other guidance systems to reach their destinations. While AGVs have greatly enhanced order fulfillment and reduced manual labor, they are limited by their dependence on fixed guidance infrastructure and cannot dynamically reroute when confronted with unexpected obstacles or changing warehouse layouts.
With breakthroughs in artificial intelligence (AI), machine learning, and advanced robotics software, material handling and supply chain companies have pioneered the use of autonomous mobile robots (AMRs). Unlike traditional AGVs, AMRs utilize cutting-edge sensors, LiDAR, onboard vision systems, and intelligent navigation algorithms. This enables AMRs to move freely throughout warehouse environments, dynamically plot their paths, and safely avoid people, machinery, and other potential obstacles. As a result, autonomous mobile robots offer a significant leap forward in scalable warehouse automation, providing greater flexibility, enhanced productivity, and improved return on investment (ROI).
Although AMRs are similar to AGVs, they differ in their flexibility, adaptability, and degree of autonomy. AMRs can create optimized routes in real time, find the most efficient way to achieve complex order picking or material transfer tasks, and modify their behavior based on real-time intelligence. Their sophisticated path-planning and collaborative nature result in far superior workflow efficiency, reduced operational costs, and seamless integration with modern warehouse management systems (WMS), compared to traditional manual or AGV-based methods.
The implementation of robotic inventory systems is a cornerstone of warehouse automation. These solutions are designed to handle repetitive, time-consuming tasks that previously consumed significant personnel hours. Decades of innovation have led to the deployment of robotic arms, conveyors, and vision-guided quality checkers. These technologies have radically improved warehouse productivity, order accuracy, and product quality, while helping companies manage higher SKU counts and faster shipping expectations.
In a typical fulfillment center or distribution facility, core activities include inventory storage, order picking, replenishment, and outbound shipment preparation. Advancements in robotics now enable automated transport of goods—minimizing the need for manual labor. AGVs and, more recently, autonomous mobile robots play pivotal roles in this environment, optimizing movement of goods, reducing travel times, and increasing operational scalability.
Transporting inventory or products between various areas—such as receiving docks, storage aisles, and shipping zones—is a key function in logistics ideally suited for AMRs. Order picking, one of the most labor-intensive and costly elements of fulfillment, is dramatically streamlined with AMR technology. Instead of workers walking long distances, AMRs can autonomously retrieve and deliver items to pickers, reducing travel time and labor requirements. Order picking robots and AMR carts shuttle products between workstations, enabling "goods-to-person" workflows that increase picking speed, accuracy, and ergonomic safety for human workers. This targeted use of automation in order fulfillment significantly accelerates processing, boosts throughput, and helps companies meet same-day or next-day delivery standards.
In zone picking, an AMR autonomously navigates to the assigned warehouse zone where the required SKU or item is stored. Workers in each zone are guided by augmented reality picklists, pick-to-light, or voice-directed picking systems integrated with the AMR’s controls. Once the item is loaded, the AMR continues to its next assignment—either delivering to additional fulfillment zones or proceeding directly to packing and shipping. AMRs equipped with modular carts make it possible to optimize batch picking, reduce touches, and enable seamless cross-docking for high-velocity operations.
Autonomous mobile robots have become integral to warehouse sortation—an essential step in facility throughput optimization. Sortation AMRs are especially valuable for cross-docking centers, e-commerce hubs, and parcel fulfillment centers. Their use spans a variety of handling technologies, including tilt-tray sorters, belt conveyor systems, and motorized rollers, all capable of supporting high-speed, high-volume order processing. Multi-bot AMR fleets can aggregate, sort, and route inventory automatically to designated chutes, lanes, or outbound staging areas, all while working collaboratively with human operators and intelligent warehouse software.
Modern AMR systems excel in both primary and secondary sortation processes, due to their flexibility and customizable programming. Primary functions include receiving parcels and distributing them into bins or totes based on order requirements, while secondary sortation consolidates items for shipment to end customers. Smart sensors, barcode scanners, and real-time inventory tracking ensure accuracy, traceability, and rapid error correction in the sortation workflow.
Popular sortation AMRs are equipped with tilt trays or cross-belt modules. They collaborate with workers and automated chutes to expedite picking and packing. When scanning a product barcode, the AMR automatically positions itself by the correct chute; the tray then tilts, releasing the item onto the proper conveyor belt or directly into an order container. The AMR then autonymously delivers consolidated orders to the designated shipping department or staging area, seamlessly integrating with other supply chain automation systems.
Beyond outbound shipping, sortation AMRs are increasingly used to automate the consolidation and organization of customer returns—a major area of inefficiency in traditional operations. Operators quickly scan items, log item numbers and quantities, and the AMR routes returned products to their appropriate storage or reprocessing locations. With configurable software, return AMRs can be reprogrammed for other warehouse functions, maximizing their utility and value.
Accurate inventory control and real-time stock visibility are critical for manufacturers and distribution centers aiming to optimize supply chain performance. Historically, inventory accuracy depended on periodic manual counts—occurring quarterly, semi-annually, or annually. These labor-intensive checks required shutdowns or slowdowns and often resulted in discrepancies tied to shrinkage, misplacement, or data entry errors.
Today, inventory management has been revolutionized by robotics and warehouse automation. Inventory scanning AMRs deploy machine vision, RFID, and advanced analytics to collect real-time data on item locations, shelf space utilization, and stock levels. AMR inventory solutions handle processes such as put-away, replenishment, and cycle counts, using built-in exception reporting to spot discrepancies and prevent stockouts or overstock situations that could lead to production delays or lost sales.
A sophisticated array of cameras and RFID readers mounted on an AMR records the location, barcode, or identifier of every SKU it passes. Integrated with warehouse management systems (WMS), these autonomous solutions enable near real-time accuracy of warehouse inventory, supporting demand forecasting, replenishment optimization, and risk reduction for out-of-stock or excess inventory. AMRs can also be deployed to conduct ongoing or scheduled cycle counts, thereby improving data integrity and ensuring an up-to-date view of all stored products, materials, or components across multiple warehouse zones.
AMR inventory scanners are especially valuable in high-velocity fulfillment centers, where demand for high-frequency cycle counting is essential to keep up with fast-moving products and SKU proliferation. Their ability to identify errors, validate put-away actions, and reconcile digital inventory records with physical goods empowers warehouse managers to minimize production downtime, boost customer service levels, and avoid losses associated with miscounts or misplaced items.
Collaborative AMRs—or cobots—are designed to optimize intralogistics by working seamlessly alongside human workers to complete a diverse range of tasks. Collaborative robots are engineered with advanced safety features, including intelligent obstacle detection, force-limiting sensors, and redundant emergency stop systems, enabling safe interaction without the need for fencing or isolation barriers commonly used with traditional industrial robots. Sophisticated programming and built-in safety standards ensure cobots can adapt to variable workflows, making them suitable for mixed-task environments found in assembly lines, fulfillment areas, or kitting stations.
Human-AMR collaboration ranges from light-touch interactions to fully shared workspaces, where robots and people operate as integrated teams. In these scenarios, collaborative AMRs deliver inventory or components, bring replenishment supplies to assembly lines, or remove completed goods for final inspection or shipment. AMRs equipped for collaboration may follow workers as they perform assembly or picking, assist with ergonomic product handling, and even learn worker preferences to improve future task assignments.
Collaborative AMRs are capable of executing complex workflows such as put-away, dynamic picking, real-time inventory counting, replenishment, and order sortation. These workflows can be tailored and integrated within enterprise resource planning (ERP) or warehouse management systems, unlocking new levels of efficiency. Collaborative robots not only reduce the walking time and fatigue for employees, but also free up staff to focus on value-added activities such as quality control, customer service, and process improvement.
The optimal performance of a collaborative robot depends on close integration with human partners who provide real-time instructions, context, and supervision. Unlike fully autonomous AMRs, cobots serve as robotic assistants, adapting their actions in support of human goals across mission-critical warehouse and production applications.
Storage picking AMRs are increasingly essential for automated warehouses, micro-fulfillment centers, and distribution operations dealing with high SKU diversity and rapid order turnaround. These robots are designed to autonomously access goods stored at multiple rack heights, often relying on specialized racking, shuttle systems, or vertical lift modules. By traversing aisles and integrating with shelving or rack-mounted infrastructure, storage picking robots retrieve bins or totes containing ordered items—accelerating fulfillment speed and boosting storage density without requiring costly facility expansion.
Customizing the dimensions, placement, and design of racking systems is a prerequisite for the successful deployment of these AMR solutions. Key factors influencing scalability include ceiling height, aisle width, the number of robots, and their integration with other systems on the warehouse floor, such as conveyor networks or packing stations. Operations may range from sites with a handful of robots supporting localized picking to large hubs deploying dozens or even hundreds of AMRs for 24/7 fulfillment. A modular approach allows companies to incrementally scale automation in response to growth and seasonal peaks.
Autonomous mobile robots are transforming not just industrial sectors, but also the hospitality, retail, and healthcare industries. In hotels, restaurants, and hospitals, AMRs handle functions such as robotic floor scrubbing, vacuuming, safe food and beverage delivery, linen transport, and waste collection. These service robots help offset labor shortages, improve operational consistency, and raise service levels by automating tedious or repetitive tasks. Common hospitality AMR applications include robotic concierges, automated room service, and intelligent delivery robots that navigate hallways and elevators autonomously.
While hospitality-focused AMR use cases are still in early adoption, ongoing innovation is rapidly expanding their capabilities. Features such as touch-free delivery, customer-facing interfaces, and seamless integration with hotel property management systems are helping hospitality providers to enhance guest satisfaction and operational efficiency.
Autonomous mobile robot (AMR) forklifts—including automated guided forklifts and self-driving pallet stackers—fulfill the core functions of traditional operator-driven forklifts with additional safety, efficiency, and flexibility. These robotic forklifts are engineered for goods movement, pallet stacking, high-bay storage, and automated pallet transport between loading docks, racking, and shipping areas. Utilizing 3D vision, LiDAR, ultrasonic sensors, and AI-driven collision avoidance, AMR forklifts operate safely alongside workers and other vehicles without requiring human drivers. They can be deployed for continuous, unmanned material handling across multiple shifts, reducing downtime and the risks associated with workplace accidents.
Key advantages of AMR forklifts include seamless integration into existing warehouse management systems and facility infrastructures. Their onboard software allows rapid adaptation to new routes, changing inventory locations, or evolving production workflows, making them ideal for dynamic logistics environments. Self-driving forklifts interface with IoT-enabled sensors and cloud-based analytics platforms to provide real-time data on warehouse performance, inventory movements, and predictive maintenance needs.
Warehouse workflows often require constant adjustments to accommodate order spikes, layout changes, or new SKUs. AMR forklifts offer intelligent, on-the-fly rerouting and logic-based decision-making in response to new picking instructions, ensuring optimal routing and minimum travel distance. As with other types of AMRs, forklift AMRs read their environment, leveraging robust sensors to guide their path safely and efficiently. When provided with new task assignments through a WMS or ERP system, they autonomously execute and complete material movements, boosting productivity and lowering the total cost of ownership for warehouse operations.
Autonomous mobile robots (AMRs) are advanced, computer-controlled robotic vehicles designed to navigate their environment independently, without relying on guidance mechanisms such as wires, reflectors, or tape. They utilize sensors, artificial intelligence, machine learning, and sophisticated software to assess their surroundings, avoid obstacles and people, and dynamically adjust their paths to complete assigned tasks.
AMRs identify and map their surroundings, enabling them to "SEE" walls, fixtures, columns, and shelving. They use this data to navigate their environment through Simultaneous Localization and Mapping (SLAM), a set of algorithms designed for mapping and determining their position within a space.
SLAM is a broad term encompassing various algorithms and technical approaches, including graph SLAM, Extended Kalman Filter (EKF) SLAM, fast SLAM, topological SLAM, visual SLAM, 2D and 3D LiDAR SLAM, and Oriented FAST and Rotated BRIEF (ORB) SLAM. The core function of SLAM is to help robots locate their position and orientation on a map while simultaneously creating that map to perform their tasks effectively.
While the concept of SLAM has been featured in science fiction for years, its practical implementation required significant technological advancements, including improvements in computer processing speed and reductions in the cost of sensors and scanners. The effectiveness of SLAM relies on two key technologies: sensor signal processing and pose graph optimization.
Pose Graph Optimization (PGO) is a technique used to refine the positions and orientations, or poses, of a robot or camera. The goal of PGO is to minimize pose errors by considering the relationships and constraints between them. A pose graph is a graphical model where nodes represent poses, and edges represent spatial constraints derived from odometry and loop closures.
Odometry constraints estimate the movement between poses, while loop closures provide constraints based on locations that an AMR revisits. By recognizing and correcting these loops, consistency is achieved between current and previous observations of a location. Pose graph optimization aims to find the best set of poses that satisfy these constraints as closely as possible, adjusting poses to reduce errors and ensure accuracy and consistency.
The initial stage of deploying an AMR involves using SLAM to map its surroundings. An operator guides the AMR through its workspace using a joystick. During this process, the AMR’s sensors detect and record the locations of walls, equipment, machinery, and other stationary elements in the environment. This data is saved by SLAM, creating a comprehensive map of the workspace with just one tour.
As the workspace evolves with new objects or equipment, the SLAM map is updated to reflect these changes. The AMR’s mapping system dynamically adjusts to incorporate new developments and ensure the map remains accurate.
During mapping, the AMR takes snapshots of its surroundings, capturing feature points represented in 3D space, including the distances from objects. These feature points form a point cloud—a 3D representation of the environment. The AMR uses this point cloud to track its position and orientation for accurate localization.
Mapping is just the beginning; localization is the next critical step. Once the environment is mapped, SLAM helps the AMR understand its location based on its surroundings. This allows the AMR to plan its path and complete its tasks effectively.
Upon activation, an AMR’s primary task is to determine its position using a combination of cameras, sensors, and LiDAR, or just one of these technologies depending on the AMR's design. In some cases, GPS is also used for additional support. The localization process involves interpreting camera images at high frame rates, typically 30 frames per second or more. SLAM uses these frames to estimate distances, match features to previously tracked points, verify against the map, incorporate new features, and accurately locate the AMR.
Visual SLAM employs cameras and sensors to provide a visual understanding of the AMR's environment. This can range from a single camera to complex setups with compound eye cameras and RGB-D cameras. These cameras aid in landmark identification and detection. Visual SLAM utilizes complex algorithms such as PTAM and ORB-SLAM for sparse feature point matching, as well as dense methods like DTAM, LSD-SLAM, DSO, and SVO, which use image brightness for navigation.
LiDAR uses laser sensors to provide precise distance measurements, making it suitable for high-speed AMRs like self-driving cars. It excels in map construction and localization by using point cloud data, which is matched using algorithms such as Iterative Closest Point (ICP) and Normal Distributions Transform (NDT). LiDAR-generated point clouds can be represented as grid or voxel maps.
To maximize effectiveness, LiDAR is often combined with other measurement methods, including wheel odometry, global navigation satellite systems, and Inertial Measurement Units (IMUs). In environments with sparse obstacles or long distances between obstacles, LiDAR may require additional support to function optimally.
The MiR600 is equipped with advanced laser scanning technology, providing 360° visibility for optimal safety. It can autonomously pick up, transport, and unload pallets without requiring additional guidance systems. The MiR600 supports downloading facility maps via CAD files or can create its own map. It is an IP52-rated AMR, offering protection against dust particles and water droplets. The MiR600 can operate near fences and open gates. It is controlled through an intuitive MiR Robot interface accessible via smartphone, tablet, or PC, and can be easily programmed without prior experience.
The MiR250 Hook is designed for towing heavy products in manufacturing environments or moving carts in hospitals. It can support loads up to 500 kg (1100 lbs.), offering a versatile logistics solution. The MiR250 Hook identifies carts using AprilTags and transports them to predefined locations. Commands for the MiR250 Hook can be quickly adjusted using a smartphone or tablet via standard Wi-Fi. Its robust base enhances maneuverability and performance.
The OPEX Sure Sort system provides a scalable and cost-effective solution for multi-line orders, package sorting, and reverse logistics. It efficiently handles small packages of various shapes, weighing up to five pounds. The system minimizes package handling with its six-sided scan tunnel, capable of reading barcodes from any angle. Sure Sort is suitable for small businesses seeking affordability or large businesses aiming to optimize operations.
In the Sure Sort system, items are placed on a belt that moves through the scan tunnel. An iBOT, a multidirectional vehicle, then deposits items into designated bins. When a bin is filled with all items for an order, the operator is notified that the order is ready for packing and shipping.
The K55 pallet stacker is designed to move and stack palletized loads at a low height and can perform cyclical or conditional routes by interacting with other AMRs, systems and people. It is the modern automated solution for transporting and organizing medium weight palletized orders. The K55 pallet stacker is adaptable to any pallet storage application, merchandise reception, and material handling system. It optimizes storage space and improves process efficiency. The K55 pallet stacker can lift 1000 kg (2204 lbs.) to a height of one meter. It uses mapping software and has exceptionally high accuracy and precision. For safety, the K55 has 360o laser scanners with PLC safety and led signaling and front touch monitoring for AMR status, potential errors, and circuits.
The MaxMover CB D 2000 is a highly maneuverable counterbalance forklift, capable of pivoting on the spot for exceptional agility. Its advanced safety system prevents overloading, accidental pushing, and dragging of loads. With a maximum payload capacity of 4,409 lbs (2,000 kg), it is versatile enough to handle various heavy loads beyond just pallets. The MaxMover CB D 2000 boasts impressive lifting speed and gradeability, making it a valuable addition to any warehousing system. Its strength and durability allow it to effortlessly reach heights of 16 ft (5,000 mm). Overall, the MaxMover CB D 2000 offers an efficient and cost-effective solution for material handling needs.
The ODM is engineered to transport totes or small loads weighing up to 300 kg (661 lbs.), making it ideal for the electronics and pharmaceutical industries. It can operate within a workspace without requiring modifications, thanks to its omnidirectional drive system, which enables smooth navigation into narrow rack aisles and allows for instant turns. The ODM features an advanced route-finding system that helps it avoid obstacles and people. If a route becomes blocked or impassable, the ODM swiftly recalculates an efficient alternative path to complete its task. A standout feature of the ODM is its swarm application, which enables a fleet of ODMs to communicate and share data, enhancing coordination and efficiency.
The primary goal of the AMR industry is to enhance employee efficiency in tasks such as picking, locating, and moving products and inventory. By operating continuously, AMRs help minimize downtime and boost productivity. Moreover, picking AMRs offer high accuracy, which reduces the likelihood of customer returns and further improves operational efficiency.
AMRs enhance operational efficiency and streamline workflows by eliminating the need for manual intervention. Their advanced routing systems reduce material handling and transportation, which lowers energy consumption and an organization’s carbon footprint. Operating around the clock without breaks, AMRs maintain high productivity levels.
Each task performed by an AMR is precise, ensuring consistency and minimizing human error. By monitoring production in real time, AMRs can identify bottlenecks, inefficiencies, and process errors, enabling management to make timely corrections and address potential issues.
Automated inventory tracking and data collection by AMRs significantly improve inventory visibility. Equipped with sophisticated sensors, cameras, and barcode scanners, AMRs conduct accurate and rapid inventory audits and provide real-time updates on stock levels and locations. Enhanced visibility helps maintain optimal inventory levels, avoiding costly stock overages or shortages.
The data collected by AMRs provides valuable insights into inventory usage, allowing businesses to make informed ordering decisions and better understand supply chain dynamics. Analyzing this data helps identify patterns and trends, enabling more efficient order processing and preparation for business changes. Ultimately, this leads to a more cost-effective and productive operation.
AMRs play a crucial role in alleviating employees from heavy-duty tasks that can be physically demanding and risky. By handling the movement of large and bulky items, AMRs improve workplace safety, reducing the risk of injuries and freeing staff to focus on tasks involving planning and problem-solving. As AMRs manage pallet movement, employees can concentrate more on quality control and order processing.
Furthermore, the use of AMRs enhances the skill level of the workforce, allowing employees to spend more time developing their skills and devising practical solutions. This transition positively impacts worker morale and attitude, as staff can engage in strategic planning, training, and programming for AMRs. As employees become more familiar with AMRs, they are better equipped to adapt to innovations and changes in the workplace.
Order fulfillment and collection are among the most time-consuming tasks in operations. The implementation of AMRs significantly enhances these processes, leading to faster and more accurate order processing. AMRs efficiently handle tasks such as picking, packaging, and shipping, thereby reducing the time required to prepare an order.
The future of manufacturing, warehousing, and retail operations is increasingly reliant on autonomous mobile robots. Organizations of all sizes and industries will need to understand how AMRs work and how they can enhance operational efficiency. Over the past decade, business operations have evolved with the integration of new technologies, and this trend will continue as we progress toward mid-century. Companies that do not embrace AMR technology risk falling behind.
Change is an inherent aspect of successful business practices. Processes that were effective a few years ago can become obsolete, making way for more efficient and adaptable methods. AMRs are designed to evolve with the changing business landscape. As facilities are updated and redesigned, AMRs can be reprogrammed and reconditioned to align with new operational dynamics.
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