The Ultimate Guide to AGV/AMR Charging Solutions

2025-06-30 | Eric

As Industry 4.0 continues to reshape manufacturing and logistics, Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) have become essential to smart factories, warehouses, and service robots. But behind their non-stop performance lies one key question: how do you charge them quickly, safely, and efficiently?

To meet the diverse demands of various industries and applications, LiFePO4 Battery Store has developed four intelligent charging solutions for AGVs and AMRs: Side Contact Charging, Floor Contact Charging, Plug-In Charging, and Wireless Charging. In this guide, we’ll break down how each solution works, where it fits best, and how to choose the right one for your operations.

✅ 01｜Side Contact Charging: Space-Saving and Precise

How It Works

The side contact charging system is available in integrated or modular designs and supports power levels from 3kW to 20kW. As the AGV or unmanned forklift approaches the docking station, side-mounted connectors automatically engage, forming a charging loop.

Key Benefits

• Customizable power output
• No manual connection required
• High contact precision
• Ideal for narrow spaces or forklift-type AGVs

Common Use Cases

Unmanned forklifts, towing AGVs, rack-moving robots, automated storage systems

✅ 02｜Floor Contact Charging: Clean and Efficient

How It Works

Using a set of brush plates and brush blocks, this system enables automatic charging upon contact. Power ranges from 3kW to 20kW and supports 24V/48V/80V/96V platforms. When the AGV docks, the brush block connects with the floor plate to start charging.

Key Benefits

• Simple structure, easy to maintain
• Excellent for clean environments
• Supports various voltages and battery specs

Common Use Cases

Shuttle AGVs in AS/RS systems, top-loading robots, inspection robots, cleaning and food delivery robots

✅ 03｜Plug-In Charging: Standardized and Reliable

How It Works

Also called the AMR intelligent plug-in charger, this setup supports 3kW to 6kW and uses a precision-guided plug-and-socket system. The AMR navigates to the charging point, and the plug connects automatically based on programmed coordinates.

Positioning Tolerances

• Rear movement: up to -50mm
• Side-to-side: ±20mm
• Vertical drift: ±7mm
• Swing angle: ±1°

Key Benefits

• Secure connection and fast engagement
• Great for heavy-duty, high-frequency AMR operations
• Modular design simplifies maintenance and upgrades

Common Use Cases

Lifting AMRs, unmanned forklifts, sorting robots, industrial transport robots

✅ 04｜Wireless Charging: The Future of Flexible Charging

How It Works

Based on magnetic resonance technology, wireless charging includes a ground transmitter and onboard receiver mounted underneath the AGV. It supports non-contact power transfer across 15–40mm of vertical distance.

Key Benefits

• No physical wear—completely maintenance-free
• One-to-many compatibility for different AGVs and voltage platforms
• Excellent for hazardous or high-dust environments

Common Use Cases

Explosion-proof inspection robots, mobile robots in harsh environments, warehouse robots, cleaning bots, and more

Smarter Charging with Centralized Scheduling

Pair your AGV/AMR charging solution with a smart dispatch system that monitors real-time battery levels, prioritizes tasks, and allocates available chargers. When a unit’s power drops below a set threshold, the system evaluates task urgency and charger availability to determine the best charging plan.

Advantages include:

• Avoids charger bottlenecks and conflicts
• Maintains high task completion rates
• Reduces idle time and labor costs
• Fully automates charging workflows

Which AGV Charging Solution Suits You Best?

Charging Type	Ideal Scenarios	Key Advantages
Side Contact	Unmanned forklifts, tow AGVs	Compact design, customizable, flexible
Floor Contact	Clean factories, shuttles	Stable contact, simple structure, cost-effective
Plug-In	Heavy AMRs, lifters, forklifts	Quick connection, modular, reliable
Wireless Charging	Harsh/dusty zones, clean rooms	Zero maintenance, fully automated, flexible

Final Thoughts: The Future Is Contactless

As automation moves forward, AGV and AMR charging is evolving rapidly—from manual plug-ins to seamless wireless charging. The right charging infrastructure can unlock higher uptime, lower costs, and smarter logistics.

Whether you're launching a new fleet or upgrading your current system, a smart charging strategy is your competitive edge.

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