32 n COMMUNICATIONS AND NETWORKING June 2024 www.drivesncontrols.com Mercedes drives wireless AGV comms to the next level At Mercedes-Benz’s factory in Ludwigsfelde, Germany, more than 70 AGVs (automated guided vehicles) are used to transport automotive parts to the assembly line. They move everything from heavy engines to smaller electronics over distances of up to 800m. Each AGV is equipped with an onboard PLC from Siemens or Schneider Electric, which ensures efficient, safe navigation. Guiding the AGVs effectively relies on good communications between the vehicles and the factory’s control system. It allows supervisors to keep track of the AGVs' whereabouts, cargos and real-time status. Previously, Mercedes-Benz used Bluetooth for its AGV communications. But it wanted to improve the system’s efficiency and to ensure that it would comply with the Machinery Regulation (EU) 2023/1230, which becomes mandatory in January 2027. “While Bluetooth worked well, we now want to enhance our AGV system to support higher throughput, fast roaming, and lower latency,” explains Maximilian Lichan from Mercedes-Benz. “We also need to comply with the soon-to-be mandatory EU safety regulations.” Mercedes provided key information such as floorplans to experts at the Swedish wireless technology developer, HMS Networks. A predictive survey performed at the site determined the number of access points required and their optimal placement. Mercedes-Benz used the updated survey to install the required power outlets and network cabling. Once the required infrastructure was in place, HMS installed and configured wireless access points based on its Anybus technology. These included Anybus PoE L2 managed switches, as well as Wireless Bolt II devices mounted on each AGV. These devices handle communications between the AGVs and the traffic control system, and connect to 12 access points mounted on the factory’s ceiling. As an AGV moves out of range of one access point, it transitions to the next, ensuring uninterrupted communications. A critical aspect to the project was its choice of operating frequency. “We wanted to use the 5GHz frequency band where we have four dedicated channels that didn’t interfere with our existing systems,” Lichan explains. “It was also convenient that the Bolt II fits in the same hole as the original Bolt (previously used on the AGVs)”. Mercedes-Benz says that its has achieved its goal of efficient, safe transportation of goods at its Ludwigsfelde factory. “Everything worked as we hoped,” Lichan reports. “The connection is very stable, and we are now able to comply with the safety machinery regulation. The support for more bandwidth has even allowed us to manage and configure the AGVs remotely, which, while not a key objective, is a nice bonus. “A key factor for us was that HMS were on hand to design and install the wireless infrastructure,” he continues. “That was important for us. We wanted to have wireless experts onsite to ensure that everything went smoothly. We’re not wireless experts, HMS are. We make cars.” n Mercedes-Benz has upgraded the wireless system that it uses to communicate with a fleet of more than 70 AGVs at one of its factories in Germany. As well as improving efficiency and safety, the new system complies with the upcoming EU Machinery Regulation. An AGV hauls a load at the Mercedes-Benz plant in Ludwigsfelde. The HMS Wireless Bolt II communications device can be seen mounted on top of the AGV. One of 12 wireless access points installed on the ceiling at the Mercedes plant
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