How to Integrate AGV Forklifts into Your Warehouse Automation System?

Take AiTEN's unmanned forklift, for example.

As warehousing and logistics increasingly demand efficiency, accuracy, and cost control, AGVs (automated guided vehicles) are becoming an integral part of automated logistics, gradually integrating into the core production and distribution processes of various enterprises. However, the successful deployment of AGVs depends not only on the technology itself but also on their level of integration with existing systems.

This article will use AiTEN's forklift robot product, the AiTEN Intelligent Unmanned Forklift, as an example to systematically explain how AGVs can be efficiently integrated into warehouse automation systems.

What Are AGV Forklifts and Why Integrate Them?

AGVs (Automated Guided Vehicles) Forklifts are autonomous mobile robots designed for material handling tasks such as pallet transport, order picking, and point-to-point delivery. Unlike conventional forklifts, AGVs navigate using SLAM-based systems, laser sensors, or vision, allowing for unmanned, repeatable, and precise operations.

As a professional manufacturer of intelligent transport robots, AiTEN's flagship product, AiTEN APx is widely applicable in manufacturing plants, warehouses, and other scenarios, making it one of the ideal solutions for achieving ‘smart warehousing.’

Step-by-Step Guide to Integrating AGV Forklifts into Your Warehouse

1. Assess Your Operational Needs

Before introducing AGVs into your workflow, first assess your current infrastructure:

• Warehouse Management System (WMS): Assess how your WMS handles inventory, order management, and real-time tracking.
• Material Handling Equipment (MHE): Identify and note other equipment that interacts with AGVs, such as conveyors, lifts, and sorters.  
• IT Systems: Assess your current IT systems, including network architecture, data storage, and communication protocols.

Before deploying AGVs, it is essential to thoroughly understand your operational processes:  

• What are the starting and ending points of daily material handling operations?
• What are the types and sizes of pallets?  
• Does the process involve shelf stacking or integration with automated equipment?

AiTEN AR stacking vehicles support pallet handling up to 2,000 kg and can perform stacking operations within 6 metres, making them suitable for high-shelf and high-frequency handling scenarios.

2. Map Your Warehouse and Define AGV Routes

Using AiTEN’s advanced multi-laser SLAM navigation, AGVs build an accurate digital twin of your facility. Clearly define:

• Navigation paths
• Pickup/drop-off points
• Charging stations

AiTEN engineers offer on-site mapping services and provide digital layout simulations to test routing logic before deployment.

3. Ensure System Integration (WMS/MES/ERP)

AGVs do not operate in isolation; they should be integrated with existing systems. The AiTEN scheduling platform can seamlessly integrate with:

• Warehouse Management System (WMS)
• Manufacturing Execution System (MES)
• Enterprise Resource Planning System (ERP)

To achieve synchronised task instructions, real-time feedback, and collaborative control.

Smooth integration with your WMS is critical for real-time data synchronisation and efficient operations:

• Real-time data exchange: Ensures real-time synchronisation of inventory levels, order status, and AGV location data.
• Workflow automation: Configure the WMS to automatically execute tasks based on AGV data.

4. Run Pilot Tests Before Full Deployment

Begin with a limited deployment in a selected zone:

• Test load handling accuracy
• Validate route traffic flow
• Adjust obstacle avoidance parameters

AiTEN provides full pilot support with remote monitoring and onsite adjustment, ensuring a successful rollout. Plan a rigorous testing phase to ensure that the AGV operates as expected in your environment.

5. Team Training and On-Site Collaboration

Although AGVs reduce manual work, your warehouse team still plays a vital role. AiTEN offers training modules covering:

• AGV Operation: Provide comprehensive training on how to operate and troubleshoot AGVs.
• System Interaction: Train employees to understand how AGVs interact with your WMS and other systems, including how to respond to system alerts or anomalies.
• Change Management: Prepare your team for workflow and process changes resulting from the introduction of AGVs.

Throughout the deployment process, we involve floor staff and senior management as much as possible, encourage them to ask questions, and schedule multiple training sessions to ensure all staff are adequately trained and familiar with the robots and systems.

Once the robots are deployed and operational, we hand them over to the Customer Success Manager, who conducts regular on-site review meetings with staff to assess robot performance metrics and address any outstanding issues.

Why Choose AiTEN AGVs?

• Navigation method: Multi-laser SLAM, positioning accuracy ±10mm
• Load capacity: Supports pallet weights ≤3000kg
• Stacking capacity: Maximum stacking height up to 7 metres
• Charging method: Automatic docking charging station, fast charging
• System compatibility: Supports WMS/MES/ERP system integration
• Safety system: 360° obstacle detection + multiple safety protections

Conclusion

Integrating AGVs with existing systems can significantly improve operational efficiency and accuracy, but this requires careful planning and execution.

Integrating AGV systems into warehouses is not just about replacing human labour, but about building an efficient, collaborative, and sustainable smart logistics infrastructure.

Unmanned forklifts such as the AiTEN AR series combine reliability, safety, and scalability, making them the preferred solution for digital and intelligent upgrades. With the right approach, your AGVs will become a valuable asset in logistics operations, elevating productivity and efficiency to new heights.

Whether you are in manufacturing, warehousing, e-commerce, or third-party logistics, AiTEN can tailor the optimal AGV automation solution for your needs.

Want to learn more? Click here to connect with our AGV experts immediately.

About AiTEN Robotics

As a company specialising in intelligent logistics solutions, AiTEN Robotics has consistently focused on the ‘smart factory’ scenario, deeply integrating technological innovation with industry needs. It has provided comprehensive services to over 200 manufacturing clients worldwide: Leveraging a full range of material handling robot product portfolios to cover diverse material handling scenarios, we have developed an industry-grade intelligent scheduling system to enable efficient collaboration among multiple devices. Through a comprehensive lifecycle service system spanning pre-sales planning, deployment and implementation to operations optimisation, we empower enterprises to achieve logistics intelligence transformation, continuously driving the digital upgrading and high-quality development of the manufacturing industry.

Contact us to explore automation solutions for your factory.