The Difference Between Low-Profile AGV and Forklift AGV

In modern industrial automation and intelligent logistics, AGVs (Automated Guided Vehicles) have become essential tools for improving material handling efficiency and reducing labour costs.

Among them, the most common types are the low-profile AGV and the forklift AGV.

This article will provide an in-depth analysis of the structure, application scenarios, advantages, disadvantages, and applicable conditions of these two types of AGVs to help you make the most appropriate selection decision

What Is Low-Profile AGV?

Low-profile AGV  is an automated guided vehicle that can ‘dive’ under shelves or material carts. It accomplishes its transport tasks by diving under the goods and using a lifting mechanism to lift the entire load.

Features of low-profile AGV:

• Compact structure with a low profile, using lifting modules to raise shelves or pallets, suitable for operation in narrow spaces;  
• Low lifting height, typically around 60mm;
• Suitable for production line integration, small-item delivery, and light-load handling scenarios.

What Is a Forklift AGV?  

A forklift AGV has a higher chassis, similar to a traditional forklift, and features a ‘fork arm’ structure similar to that of a forklift. It can lift and transport pallets, frames, and other goods from the side or front, with a certain lifting height and stacking capacity, akin to an automated version of a traditional forklift.

Structural features: Equipped with a mast, forks, and a hydraulic lifting system, the vehicle has a higher body (lifting height can reach over 3 metres) and stronger load-bearing capacity (1-5 tonnes).  

Features of a forklift AGV:  

• Strong load-bearing capacity;  
• Compatible with standard pallets (e.g., Euro-standard, US-standard), no need for customised racks;
• Supports loading and unloading operations on high-bay racks, suitable for warehouse inbound and outbound operations;  
• Typically requires larger passage space, suitable for large warehouses or workshops with standardised layouts.  
• Suitable for palletised cargo stacking and heavy-duty material handling.

Comparison of the Core Differences Between Low-Profile AGV and Forklift AGV?  

1. Applicable cargo types:

• Low-profile AGV: Primarily used for transporting standard pallets, material carts, and material racks (with sufficient clearance at the bottom).
• Forklift AGV: Suitable for transporting large items, heavy-duty pallets, and material racks of specific dimensions etc.

2. Cargo handling height:

• Low-profile AGV: Typically handles cargo at ground level (primarily for transportation, not stacking).

• Forklift AGV: Can pick up and place at different heights (ground level, shelves, conveyor lines) and has stacking capability.

3. Load capacity:

• Low-profile AGV: Low-profile AGVs typically have lower load capacity, generally < 1.5 tonnes (common range: 500kg - 1000kg).
• Forklift AGV: Higher load capacity, typically > 1 tonne, up to several tonnes.

4. Aisle Requirements:

• Low-profile AGV: Relatively narrow aisles (due to low height, no need to consider mast lifting space).
• Forklift AGV: Wider aisles required (considering mast width, lifting height, and turning radius).

5. Primary Application Scenarios:

• Low-profile AGV: Continuous material handling on production lines (JIT/JIS), transporting materials from line-side warehouses to production lines, inter-process material transfer, and e-commerce order picking and consolidation. Low-profile AGVs are suitable for high-density warehouses, such as e-commerce warehouses and 3C electronics warehouses.
• Forklift AGV: Pallet in/out operations within warehouses, heavy-duty material handling across regions, stacking operations, and loading/unloading vehicles. Examples include raw material warehouses and finished goods warehouses in manufacturing.

6. Replacement targets:

• Low-profile AGV: Traditional manual pallet trucks, tow trucks, and some roller conveyor lines.
• Forklift AGV: Traditional manual forklifts (counterbalanced, reach-type, etc.).

7. Automation Integration Level:  

• Low-profile AGV: High, commonly used to build highly automated continuous conveying systems.  
• Forklift AGVs: High, but more focused on automating heavy manual material handling.  

8. Cost and Investment:  

• Low-profile AGV: Relatively simple structure, lower per-unit cost, suitable for small and medium-sized enterprises or small-scale applications, low deployment cost, no need for large-scale warehouse environment modifications.
• Forklift AGV: Complex mechanical structure, high load capacity, higher per-vehicle cost.  

9. Typical Advantages:  

• Low-profile AGV: Flexible, efficient, space-saving, suitable for narrow aisles, dense handling, and assembly line operations.  
• Forklift AGV: Powerful functionality (lifting, stacking), high load capacity, directly replaces manual forklift operations.

How to Choose the Right Type of AGV?  

The choice between a low-profile AGV and a forklift AGV should be based on specific business needs, logistics processes, and on-site space conditions:  

• If your logistics system requires frequent small-batch turnover, has limited space, and handles customised material carts, we recommend using a low-profile AGV;  
• If your work environment involves heavy-duty pallet handling and loading/unloading from high shelves, we recommend using a forklift AGV.

Both types of AGVs often work in tandem within complex automated logistics systems, each leveraging their strengths to collectively complete the entire material handling process. For example, low-profile AGVs handle precise delivery on production lines, while forklift AGVs manage bulk material intake, outflow, and stacking in warehouse areas.

總結

The selection of AGVs has a direct impact on automation efficiency. Low-profile AGVs excel in internal delivery on production lines due to their flexibility and lightweight characteristics, while forklift AGVs are suitable for complex warehousing and storage tasks due to their powerful load-bearing capacity and stacking functions.

Choosing the right type of AGV will lay a solid foundation for your smart logistics system.

AiTEN Robotics, headquartered in Suzhou, China, is a global leader in autonomous industrial vehicles (AMR/AGV) and logistics automation solutions. AiTEN Robotics has developed ten product series to meet the needs of full-stack material handling scenarios. AiTEN Robotics has deployed more than 200 projects in over 30 countries and regions, and is trusted by numerous Fortune 500 companies across industries such as automotive, food and beverage, chemicals, pharmaceuticals, manufacturing, and third-party logistics, enhancing operational safety, efficiency, and future readiness.

Contact AiTEN to learn how our innovative autonomous forklifts and intelligent systems can transform your material handling processes.