Developing Automated Guided Vehicle Systems (AGVS) for over 25 years


Corecon has developed a new AGV line to meet the market demands for a small and economical AGV for light to medium weight loads without sacrificing vehicle quality or reliability. The Flex Cart AGV has a low profile design which makes it a good choice to move carts or trays for part and tote transport. The Flex Cart is also available as a tow vehicle. The Flex Cart AGV is equipped with an on board charger which plugs into a standard 120 volt outlet through a retractable power cord. An optional opportunity charge shoe allows for automatic charging of the AGV when supporting multiple shift operations. The maximum load carrying capacity and towing capacity is 3,000 pounds with a maximum velocity of 115 feet/minute. The 2,000 pound capacity Flex Cart has a maximum velocity of 165 feet/minute and the 1,000 pound capacity has a maximum velocity of 220 feet/minute. Vehicle options include side bumper/release bar, opportunity battery charging, onboard battery charging, sealed batteries, and radio communication.
AGV velocity is always an important factor in selecting an AGV system. The number of vehicles required in an AGV system is usually directly related to the maximum velocity of the vehicle. The number of AGVs required for system throughput is usually decreased as the vehicle maximum velocity is increased. The highest maximum velocity which can be safely used in an AGV application is usually the best choice since it reduces the system cost. However this is not true for the following unique AGV application. 

A leading aircraft manufacturer wanted to create a moving assembly line for their aircraft fin and stabilizers. Assembly lines have historically used overhead conveyors, flat top conveyors, or tow chain systems to move the product through the assembly process. This manufacturer chose AGVs because they allow each individual product to move at the appropriate speed independent of the other products. AGVs also offer the flexibility of easily removing a product from the line without stopping the line. The aircraft fin and stabilizer assembly lines have a long assembly process time but do not travel a large distance during the assembly process so they require an AGV with a very low minimum velocity. Corecon developed an AGV to meet these requirements and named it the “Imperceptible Motion AGV”. This AGV is capable of moving so slowly the movement of the AGV it is not easily perceived by the naked eye. Minimum velocity of the AGV is 1 inch/minute with velocity accuracy within 1 percent.  This accurate very low speed allows intricate assembly processes to be efficiently performed on a moving assembly line. This AGV is also equipped with line indicator lights, zero play hitch, powered opportunity charging shoe, sealed fast charge battery, and laser bumper. Maximum AGV velocity is 120 feet/minute which is used for traveling to the unload/load station and back to the assembly area. This maximum towing capacity of the AGV is 12,000 pounds.
Toyota wanted to automate the delivery of the headliner and instrument panel dollies (with parts and fixtures) from the loading dock to the production line without altering the production line equipment. The challenging part of the application was to move the three dollies which have a total weight of 18,000 pound at 180 feet/minute so the system throughput could be attained with two AGVs. Corecon met this challenge by increasing the capacity of its model E-275 product line. The E-275 is an economical and very durable AGV but it was originally engineered to tow 6,500 pounds. Corecon reengineered the E-275 vehicle to tow up to 20,000 pounds at 180 feet/minute and included many new design features such as opportunity charging, sealed fast charge batteries, radio communication, horizontal and vertical laser bumpers, optical communication, and CAT 3 safety rating. This new E-275 AGV is engineered for high reliability, low maintenance, and long life. Swing out/lift off doors provides access for servicing the AGV components. Corecon once again exceeded the customer requirements and received high accolades from Toyota for delivering a highly reliable system and successfully installing it in a production environment without interruption to their production.
A leading plastic injection molding manufacturer wanted to automate the box and pallet handling in its molding room. Even with eighteen molding machines the throughput requirements of the system could be accomplished with one AGV but this meant that the same AGV was required to transport layers of empty boxes, deliver empty pallets to the line, stack layers of full boxes six high on the pallet, and also deliver the palletized full boxes to the warehouse. This problem was further complicated by the existing pallets having several different designs. Could all these requirements be met by one AGV? Corecon said yes, and engineered a rear load AGV with special shifting forks which rotated to the vertical position to clamp the box layers and rotated back to the horizontal position for pallet handling. The forks are designed with two unique and adjustable clamping forces so the empty boxes are not crushed and the full box layer is not dropped. The full pallets are delivered to the warehouse rack and the AGV system keeps track of the inventory. This is just another example of Corecon meeting and exceeding an unusual customer requirement. Challenge Corecon with your AGV application requirements.
Eagle E275 Tugger
Box Clamp AGV
Flex Cart


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