By integrating its proprietary technology into autonomous guided vehicles (AGVs), Phoenix Contact is achieving safer, faster, and smarter production workflows.
At Phoenix Contact’s G31 production hall, a new era of industrial efficiency is already in motion. As assembly workers begin their day, autonomous guided vehicles (AGVs) spring into action – delivering materials to machines, navigating tight corridors, and stopping instantly when people cross their path.
This seamless dance between man and machine is powered entirely by Phoenix Contact’s automation and connectivity technologies.
Automation powered by PLCnext Technology
To bring their AGV fleet to life, Phoenix Contact built a fully autonomous system based on seven core pillars of automation: Control, Safety, Security, Navigation, Electrification, Communication, and Energy. Each function was developed using components from Phoenix Contact’s extensive product portfolio.
At the heart of each AGV is PLCnext Control, managing everything from routing to load transfer. This is paired with the Axioline Smart Elements series, compact I/O modules that save up to 75% space in control cabinets, offering robust and flexible signal handling for a mobile application.
Safety and cyber protection: built-in and certified
In dynamic production environments, AGVs must safely interact with people. Phoenix Contact addressed this by incorporating the AXC F XT SPLC 1000 safety controller, enhancing the standard PLCnext Control with real-time safety functions.
But it’s not just physical safety that matters. Cybersecurity is increasingly critical in connected production systems. Here, Phoenix Contact’s AGVs benefit from TÜV-certified protection against cyber threats, complying with IEC 62443-4-1 ML3 and IEC 62443-4-2 SL2 standards, ensuring business continuity even under attempted digital intrusions.
Navigation and connectivity: seamless and scalable
One of the biggest technical challenges was reliable and cost-effective path planning. While proprietary solutions offered precision, they often lacked flexibility and came with high costs. Instead, Phoenix Contact leaned into the openness of PLCnext Technology, using standard interfaces like MQTT, REST, and OPC UA to enable efficient and adaptable communication across systems.
Communication between each AGV and the central fleet management system is handled via the FL WLAN 1010 radio module, ensuring uninterrupted data exchange and vehicle coordination.
Power and energy – made to move
Phoenix Contact’s AGVs are fitted with inductive charging systems that eliminate the need for manual recharging, improving uptime and workflow efficiency. Internal electronics are supported by in-house DC/DC converters, delivering a stable 24V supply to all control components.
Energy usage, battery health, operational status, and error diagnostics are continuously monitored through a CAN protocol, fully managed by the PLCnext Control. This data provides clear insights into performance and supports predictive maintenance.
Smarter workflows, real-world value
Since implementing the AGV system, Phoenix Contact has significantly reduced material delivery times and improved inventory movement within production – the result of integrating hardware and software in a purpose-driven, real-world setting.
More importantly, the project has given Phoenix Contact valuable experience in deploying AGV systems using only its automation ecosystem.
By combining smart automation, safety, cybersecurity, and energy management in a single platform, Phoenix Contact is redefining what’s possible in modern industrial environments.
