AGV Brake Motor and Power Selection Standard Technical Analysis: From

In intelligent manufacturing logistics systems, the selection of the power system for Automated Guided Vehicles (AGVs) directly determines the equipment's operational efficiency, safety, and service life. This article provides a systematic technical reference for engineering designers by deeply analyzing the professional selection methods for AGV brake motors and drive motors from three dimensions: mechanical calculation basis, selection decision matrix, and special working condition handling.

I. Brake Motor Selection Standard: A Safety-First Decision System

As a key safety component of AGVs, the configuration of the brake system must be comprehensively determined based on both load grade and AGV type. The core principle is to ensure that the stopping distance during an emergency stop meets safety requirements.

1.1 Basic Selection Matrix

According to the load range and AGV structure type, the configuration of the brake motor follows the technical specifications below (Table 1):

Load Range	Underride AGV	Rear-Traction AGV (High Precision ±10mm)	Rear-Traction AGV (Standard Precision)	Backpack AGV (High Precision ±10mm)	Backpack AGV (Standard Precision)	Differential Drive AGV (High Precision ±10mm)	Differential Drive AGV (Standard Precision)
≤300Kg	Not Required	Not Required	Not Required	Required	Required	Required	Required
＞300Kg~800Kg	Not Required	Not Required	Not Required	Required	Required	Required	Required
＞800Kg~1000Kg	Not Required	Required	Required	Required	Required	Required	Required
＞1000Kg	Required	Required	Required	Required	Required	Required	Required

Core Logic: As the load increases, inertial force grows linearly. The configuration threshold for the brake system is positively correlated with the load grade. For AGVs with high precision requirements (±10mm), the configuration threshold is lower due to stricter positioning error requirements.

1.2 Mandatory Configuration Conditions

Under the following working conditions, the brake system must be configured regardless of load size:

The emergency stop circuit is connected to a close-range obstacle detection signal, requiring fast stopping response.
Process requirements explicitly specify a stopping distance (e.g., <specific value>), which cannot be met by conventional coasting.
The operating environment has a slope (>0°), requiring prevention of AGV rollaway.
The load consists of precision equipment or hazardous materials, requiring absolute assurance of parking stability.

1.3 Brake Force Calculation Basis

The design of the brake system must satisfy the dynamic balance equation:

 $F_{b r ak e} = (m_{A G V} + m_{l o a d}) \times g \times μ \times cos (θ) + (m_{A G V} + m_{l o a d}) \times g \times sin (θ)$

Where:

•

F_{b r ak e}

: Braking force (N)

•

m_{A G V}

: AGV self-mass (kg)

•

m_{l o a d}

: Rated load mass (kg)

•

g

: Gravitational acceleration (9.8 m/s²)

•

μ

: Ground friction coefficient (0.6~0.8 for conventional cement floors)

•

θ

: Slope angle of operation (rad)

Engineering Experience Value: For conventional flat conditions (

θ = 0

), the safety factor for braking force should be 1.2, i.e.,

F_{d es i g n} = 1.2 \times F_{b r ak e}

II. Drive Motor Power Selection: Precise Calculation Based on Energy Balance

Drive motor power selection must be based on load analysis, motion characteristics, and transmission efficiency. The conventional selection standard applies to AGV systems within the speed range of <specific value>.

2.1 Conventional Selection Matrix

Standard motor power configuration for different AGV types across load grades (Table 2):

Load Range	Towing AGV (Unidirectional)	Towing AGV (Bidirectional)	Backpack AGV (Unidirectional)	Backpack AGV (Bidirectional)	Differential Drive AGV (Bidirectional)
≤300Kg	100W (1:30)	100W (1:30)	100W (1:30)	100W (1:30)	200W (1:40)
＞300Kg~500Kg	100W (1:30)	100W (1:30)	200W (1:30)	100W (1:30)	400W (1:40)
＞500Kg~600Kg	200W (1:30)	100W (1:30)	400W (1:30)	200W (1:30)	400W (1:40)
＞600Kg~800Kg	200W (1:30)	100W (1:30)	400W (1:30)	200W (1:30)	750W (1:40)
＞800Kg~1000Kg	200W (1:30)	100W (1:30)	—— (Requires Calculation)	400W (1:30)	750W (1:40)
＞1000Kg~1600Kg	400W (1:30)	200W (1:30)	—— (Requires Calculation)	400W (1:30)	—— (Requires Calculation)

Speed Ratio Selection Basis: The reduction gear ratio (e.g., 1:30) must meet torque matching requirements, i.e.,

T_{o u tp u t} = T_{m o t or} \times i \times η

, where

η

is the transmission efficiency (conventional 0.85~0.9).

2.2 Mathematical Model for Power Calculation

2.2.1 Basic Power Calculation Formula

The power requirement for AGV operation at constant speed:

 $P_{ba se} = \frac{( F ^{f r i c t i o n} + F ^{w in d} ) \times v}{3600 \times η ^{t o t a l}}$

Where:

•

P_{ba se}

: Basic drive power (kW)

•

v

: Operating speed (m/h), convert km/h to m/h (×1000)

•

η_{t o t a l}

: Total efficiency of the transmission system (decimal)

2.2.2 Slope Power Compensation

When the AGV operates on a slope, additional slope compensation power is required:

 $P_{s l o p e} = \frac{( m ^{A G V} + m ^{l o a d} ) \times g \times sin ( θ ) \times v}{3600 \times η ^{t o t a l}}$

2.2.3 Acceleration Power Compensation

Considering the power demand during startup acceleration:

 $P_{a cc} = \frac{( m ^{A G V} + m ^{l o a d} ) \times a \times v}{3600 \times t ^{a cc} \times η ^{t o t a l}}$

Where

a

is acceleration (m/s²),

t_{a cc}

is acceleration time (s), conventionally 2~5s.

2.2.4 Total Power Requirement

The final motor power selection must satisfy:

 $P_{m o t or} = (P_{ba se} + P_{s l o p e} + P_{a cc}) \times K$

Where

K

is the power safety factor, conventionally 1.5.

2.3 Special Handling for Unconventional Working Conditions

The following conditions do not apply to the conventional selection standard and require specialized mechanical calculations:

Towing AGV:

• Cart length > <specific value> or width > <specific value> (consider turning radius and inertia)

• Number of towed carts > <specific value> (consider tension distribution in multi-cart linkage)
Load Characteristics:

• Load mass > <specific value> (exceeds conventional load grade)

• Load center of gravity offset > <specific value> (consider overturning moment)
Motion Parameters:

• Operating speed > <specific value> or < <specific value> (exceeds conventional speed range)

• Acceleration time < <specific value> (consider inrush current)
Environmental Factors:

• Operating slope > <specific value> (requires increased slope compensation power)

• Ambient temperature < <specific value>°C or > <specific value>°C (consider motor power derating)

• Dust concentration > <specific value> mg/m³ or humidity > <specific value>% (consider protection level)

III. Engineering Application Guide for Selection Standards

3.1 Systematic Implementation of the Selection Process

Define Working Conditions: Clarify basic parameters such as AGV type, load range, operating speed, and environmental conditions.
Preliminary Selection: Determine the initial plan for motor power and brake configuration based on the conventional selection matrix.
Mechanical Calculation: Verify the rationality of the preliminary selection by calculating actual power requirements based on the mathematical model.
Special Verification: Check for the presence of unconventional working conditions and perform specialized calculations if necessary.
Final Determination: Determine the optimal selection plan by integrating technical feasibility and economic considerations.

3.2 Measurement Requirements for Key Parameters

Parameter Category	Measurement Tool	Accuracy Requirement	Measurement Frequency
Load Mass	Electronic Scale	±1%	Once per batch
Operating Speed	Laser Speed Gun	±0.1m/min	Once per vehicle
Slope Angle	Inclinometer	±0.1°	3 times per area
Friction Coefficient	Dynamometer	±5%	Once per surface type

3.3 Visual Reference for Selection Standards

[Image Position: AGV Brake Motor and Power Selection Standard Reference Chart]

IV. Technical Verification and Quality Control

4.1 Motor Performance Testing

The following performance tests are required after motor selection:

Rated Load Test: Continuous operation for 4 hours under rated load; measure motor temperature rise (<specified value>).
Overload Test: Operation for 1 hour at 1.2 times rated load; no abnormal noise or overheating.
Brake Performance Test: Emergency stop at rated speed; stopping distance must meet design requirements (conventional <specific value>, v in m/min).
Durability Test: 1000 start-stop cycles; braking torque attenuation rate <specified value>.

4.2 Dynamic Maintenance of Selection Standards

Regular Review: Update the selection standard every 2 years based on technological developments and application experience.
Case Accumulation: Establish a case database to provide references for similar projects.
Supplier Collaboration: Maintain technical communication with motor suppliers to promptly obtain new product information.

AGV Brake Motor and Power Selection Standard Technical Analysis: From Selection Basis to Engineering Practice

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AGV Brake Motor and Power Selection Standard Technical Analysis: From Selection Basis to Engineering Practice

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