AGV – Automated Guided Carts

FULLY CUSTOMIZED AGVs for heavy-duty applications

Morello specializes in the design and manufacture of fully customized heavy-duty AGVs (Automated Guided Vehicles) engineered to meet the specific requirements of a wide range of industrial sectors. Drawing on advanced engineering expertise, we develop AGV carts capable of handling heavy loads ranging from 2 to 1,000 tons, providing automated, efficient, and reliable material handling for demanding operations.

These self-guided, wheeled vehicles are designed to operate autonomously, without the need for human intervention during transport. Depending on the application, they can run on embedded tracks or guided paths, ensuring precise navigation and seamless integration into existing industrial workflows.

Morello’s automated guided carts enhance internal logistics by delivering flexible, high-performance automation tailored to each production environment. Each solution is developed according to load capacity, dimensions, center of gravity, route, operating area, safety requirements and required level of software integration.

KEY ADVANTAGES of AGV carts

Morello’s AGV systems help companies improve productivity, safety and operational control in heavy-load handling processes. Key advantages include:

• reduced labor costs
• enhanced workplace safety
• greater accuracy and operational efficiency
• reduced risk of damage to products and infrastructure
• safe operation in hazardous or high-risk environments, such as explosive zones
• improved continuity in repetitive material handling cycles.

NAVIGATION and guidance technologies

Morello’s automated guided carts can be equipped with a wide range of navigation technologies. The most suitable solution, or combination of solutions, is selected according to technical requirements, operating conditions, plant layout and budget constraints.

SOFTWARE INTEGRATION with WMS, MES and plant systems

To maximize flexibility and performance, Morello integrates both proprietary and third-party software platforms. This allows each automated cart system to be aligned with the customers’ production processes, from route planning to mission management and safety logic.

Our software solutions can support omnidirectional automated guided carts, robotic carts using multiple navigation technologies simultaneously, integration with Warehouse Management Systems (WMS), connection with Manufacturing Execution Systems (MES) and interoperability with other automated material handling equipment.

This makes each heavy-duty AGV solution suitable for advanced industrial environments where automated transport must communicate with production systems, warehouse workflows and other machines inside the plant.

AGV's vs Manual trolley

Compared with a manual trolley or operator-driven handling equipment, an AGV can reduce repetitive tasks, improve route consistency and limit operator exposure during heavy-load movement. This is especially important when loads are large, expensive, difficult to maneuver or moved frequently within the same production flow.

A manual solution may be suitable for occasional handling operations, while an AGV becomes more effective when the process requires automation, repeatability, tracking, integration with plant software and higher safety control. For applications with specific height constraints, a low-profile AGV can be developed to support handling under molds, tooling, machinery or other loads with limited clearance.

OUTDOOR AGV for molds and dies

Morello has developed AGV solutions for outdoor heavy-load handling, including a 40-ton system designed for molds and dies. This application supports automated movement where precise control, safety and reliable performance are essential. Explore the project to see how this solution was applied in a demanding industrial context.

CUSTOM AGV design for industrial automation

Morello designs high-capacity AGV carts for hazardous environments and a wide range of specialized industrial applications. Each system can be customized according to payload, dimensions, deck height, steering system, navigation technology, software interface, safety devices and operating conditions.

By combining mechanical engineering, automation expertise and software integration, Morello develops AGV solutions that help companies reduce handling costs, boost productivity and improve safety in heavy-duty industrial logistics.

Contact Morello’s team to discuss your application and identify the most suitable automated guided cart for your handling requirements.