11.27.2025 / 6-minute read

Automated Multi-Floor Material Handling for Home Goods: AGV & Reciprocating Lift System

Project Overview

This case study details a turnkey automated material handling solution implemented for a leading home goods manufacturer.

The integrated system seamlessly connects production and storage across multiple floors using Underride Lifting AGVs, a Reciprocating Lift, Roller Conveyor Lines, and standardized Pallets, all managed by a central software platform.

Faced with challenges of labor-intensive transportation, spatial constraints, and the need for greater process flexibility, the manufacturer adopted this solution to achieve 24/7 automated operation, enhance safety, and significantly improve intra-logistics efficiency.

Basic Parameters

Component	Parameter	Value / Specification	Notes
Underride Lifting AGV	Payload Capacity	1,000 kg	Suitable for loaded home goods pallets
	Navigation Method	Laser SLAM	Enables flexible, markerless navigation
	Positioning Accuracy	±10 mm	Critical for precise docking with conveyors and lift
	Lift Height	50 mm	Standard for pallet jack-style operation
Reciprocating Lift	Load Capacity	1,500 kg	Exceeds AGV + palletized load weight for safe operation
	Platform Interface	Motorized Roller Conveyor	Ensures seamless pallet transfer
	Control Interface	Automated with AGV system	Enables fully automated operation
Roller Conveyor Line	Load Capacity	1,500 kg	Matched with lift capacity
	Height	Adjustable	Customizable to match AGV and lift platform heights
Overall System	Control System	Central Scheduling & WMS/MES Integration	Enables real-time task management and data exchange

Challenge

Labor-Intensive Processes: Heavy reliance on manual labor and forklifts for vertical transportation was inefficient, costly, and posed safety risks.
Spatial Constraints: The existing layout made it difficult to implement fixed conveyor systems for cross-floor transportation without major and costly structural modifications.
Demand for Flexibility: Production schedules and product mixes frequently changed, requiring a material handling system that could adapt quickly without significant downtime or reconfiguration.

Workflow

AGV Transport & Pickup: The control system dispatches an Underride Lifting AGV to a pickup location (e.g., end-of-line production). The AGV navigates to the location, slides its forks under the waiting pallet, lifts it, and transports it to the reciprocating lift’s entry station .
Precision Docking & Transfer: The AGV aligns with the lift’s entrance with high precision (±10mm). The roller conveyor on the lift’s platform and at the station synchronize, pulling the pallet from the AGV into the lift cabin. The AGV is then free to execute its next task.
Vertical Conveyance: Once the pallet is securely inside, the lift door closes. The reciprocating lift then moves vertically to the designated target floor (e.g., storage level), all controlled by the central scheduler.
Unloading & Final Delivery: On the target floor, the lift door opens. Another Underride Lifting AGV (or the same one, if scheduled) docks with the lift. The roller conveyors transfer the pallet onto the waiting AGV, which then delivers it to its final destination, such as a storage buffer or shipping staging area.

Software System

Intelligent Traffic Management: This system is responsible for the real-time scheduling and dispatch of all AGVs, managing their routes to avoid collisions and optimize traffic flow .
Lift Control Module: Integrates the reciprocating lift as a managed resource within the system, coordinating its movements with AGV arrivals and departures.
WMS/MES Integration: The platform communicates seamlessly with the plant’s management software (e.g., MES). This allows the system to receive transport orders directly and provide real-time status updates on material location, enabling a closed-loop data flow and end-to-end visibility .

Solution

Underride Lifting AGVs: A fleet of these robots navigates the production and warehouse floors. They are designed to slide underneath and lift standardized pallets placed on stands, transporting them to and from the reciprocating lift .
Reciprocating Lift: This heavy-duty vertical conveyor acts as the system’s backbone for moving pallets between floors. It features an integrated roller conveyor platform for smooth transfer .
Roller Conveyor Lines: These are installed at the interface points with the AGVs and within the reciprocating lift, ensuring frictionless and aligned transfer of pallets.
Standardized Pallets & Interface: The entire system is designed around standardized pallet sizes and heights, ensuring compatibility across all AGVs, lifts, and conveyors.
Unified Control System: A central Intelligent Traffic Management System orchestrates the entire process. This system manages AGV dispatch, lift operation, and communicates with the plant’s higher-level Warehouse Management System (WMS) or Manufacturing Execution System (MES), creating a fully integrated and data-transparent logistics loop .