What Are the Main Types of Warehouse Robots and How Are They Used
Warehouses today use a range of robots and automated systems to improve speed and accuracy. Common types include automated guided vehicles (AGVs), autonomous mobile robots (AMRs), ARM Warehouse Robot, palletizers, depalletizers, conveyor systems, sorting robots, packing robots, drones, collaborative robots, and automated forklifts.
Each robot type serves a unique role in warehouse operations, from moving goods to improving order accuracy.
Key Takeaways
Warehouse robots like AGVs, AMRs, robotic arms, drones, and cobots automate tasks to boost speed, accuracy, and safety in warehouses.
AGVs follow fixed routes and work well in stable layouts, while AMRs navigate freely and adapt to changing environments, offering more flexibility.
Robotic arms handle picking, packing, and sorting with precision, reducing errors and freeing workers for higher-value tasks.
Drones and collaborative robots improve inventory tracking and worker safety by performing risky or repetitive jobs alongside humans.
Using warehouse robots leads to higher productivity, lower labor costs, better order accuracy, and safer workplaces.
Mobile Robots
AGVs
Automated Guided Vehicles (AGVs) move goods along fixed routes in warehouses. These robots follow paths marked by wires, magnetic strips, or lasers. AGVs work best in stable environments where tasks do not change often. They help transport pallets, cases, and materials between storage and shipping areas.
AGVs require changes to warehouse layouts for installation. This process can take time and cost money.
They operate on set paths and stop if they meet an obstacle. Human workers may need to help them continue.
AGVs handle repetitive tasks, such as moving pallets or replenishing stock, which reduces labor costs and increases safety.
By running 24/7, AGVs boost productivity and lower downtime.
AGVs can increase operational efficiency by up to 30% in the first year of use. Some warehouses have seen productivity rise by 50% after adding AGVs and other robots.
AGVs also improve inventory accuracy by working with warehouse management systems. They help reduce errors and keep track of goods in real time.
AMRs
Autonomous Mobile Robots (AMRs) use advanced sensors, cameras, and artificial intelligence to move freely in warehouses. Unlike AGVs, AMRs do not need fixed routes or special floor markings. They create maps of their surroundings and plan their own paths.
AMRs avoid obstacles and change routes on their own. This makes them ideal for busy or changing warehouse layouts.
They use LiDAR, cameras, and machine learning to sense their environment and make decisions in real time.
AMRs can take on new tasks with simple software updates, making them flexible and easy to scale.
AGV Characteristics | AMR Characteristics | |
|---|---|---|
Navigation | ||
Integration | Fast, easy reconfiguration | |
Cost | Lower initial, higher modification cost | Higher initial, lower modification cost |
Ideal Use | Stable, predictable layouts | Dynamic, changing environments |
AMRs help reduce worker strain by taking over long-distance travel and repetitive tasks. They also improve safety by avoiding collisions and adapting to busy environments. Studies show that AMRs can operate safely alongside people, lowering the risk of injuries and making warehouses safer.
Mobile Rack AMRs
Mobile rack AMRs carry entire shelves or racks to picking stations. This "goods-to-person" method saves time and energy for workers. Instead of walking long distances, workers stay at their stations while robots bring the items to them.
Mobile rack AMRs increase picking speed and accuracy. They present only the correct items, reducing mistakes.
These robots allow for flexible warehouse layouts and better use of space compared to traditional shelving.
They are easy to scale. Adding more robots or changing the layout does not require major downtime.
Mobile rack AMRs help warehouses handle more orders with fewer errors. They also lower labor costs by reducing manual transport tasks.
However, some challenges exist. Narrow aisles and complex layouts can make navigation harder for these robots. Smaller warehouses may not benefit as much due to the high initial investment. Careful planning, staff training, and infrastructure upgrades are important for successful use.
Shuttle AMRs
Shuttle AMRs move materials such as pallets, bins, and boxes within warehouses. They often work as part of Automated Storage and Retrieval Systems (AS/RS). Shuttle AMRs can handle high-turnover stock, perishable goods, and items in temperature-controlled areas.
These robots serve as buffers, storing goods until needed for production or shipping.
Shuttle AMRs use different modules to transport a variety of items, from raw materials to finished products.
They connect with warehouse management software to automate deliveries and track inventory.
Key performance metrics for shuttle AMRs include:
Cycle times (how fast they complete tasks)
Throughput (number of cycles per hour)
Storage density (how much they store in limited space)
Operational uptime (ability to run non-stop with automatic charging)
Shuttle AMRs help warehouses run smoothly by automating low-value transport tasks and reducing manual labor.
Automated Forklifts
Automated forklifts lift and move pallets without human drivers. They use sensors, cameras, and AI to navigate and avoid obstacles. These forklifts operate day and night, increasing efficiency and reducing downtime.
Aspect | Autonomous Forklifts | Traditional Forklifts |
|---|---|---|
Safety | Reduce accidents by up to 90% with 360° sensors and emergency stop systems | Account for 25% of warehouse accidents due to operator error |
Eliminate human error, fatigue, and distraction | Safety depends on operator training and PPE | |
Operational Efficiency | Operate 24/7 without breaks, e.g., 8 hours after 2-hour charge | Require breaks and skilled operators, causing downtime |
Use precise navigation for millimeter-level positioning | Productivity varies with operator skill | |
Integrate with warehouse management systems for smart task scheduling | Manual task handling increases delays |
Automated forklifts improve workplace safety by removing the risk of human error. They use collision avoidance systems and emergency brakes to prevent accidents. Over their lifespan, automated forklifts have shown far fewer incidents than manual ones.
Automated forklifts help warehouses save on labor costs, increase throughput, and maintain high safety standards.
📈 Market Growth Snapshot
Metric | Value | Timeframe | CAGR |
|---|---|---|---|
USD 15.23 billion | 2024 | - | |
Warehouse Robotics Market Projection | USD 55.74 billion | 2033 | 15.51% (2025-2033) |
- | Through 2030 | 20.5% | |
USD 3.5–10.6 billion | 2020–2030 | 12.5% (2021–2030) |
The warehouse robotics market is growing rapidly, driven by e-commerce and the need for faster, safer operations. Mobile robots like AGVs and AMRs are leading this growth, offering flexible and efficient solutions for modern warehouses.
ARM Warehouse Robot
What Is an ARM Warehouse Robot
An ARM Warehouse Robot uses a robotic arm to automate tasks such as picking, packing, and sorting in warehouse environments. These robots come in different designs. Some have articulated arms that mimic human movement, while others use gantry arms for straight-line actions. The end-effector, or gripper, acts as the robot’s hand. It can grasp items using grippers, suction cups, or magnets. Sensors like vision systems and proximity detectors help the robot see and sense its surroundings, making movements precise and safe.
Key components of an ARM Warehouse Robot include:
The shoulder, allowing the arm to extend and retract.
The elbow, which lets the arm bend.
The wrist, responsible for rotation and orientation.
The gripper, which interacts with objects.
ARM Warehouse Robots combine these parts to handle a wide range of warehouse tasks with speed and accuracy.
How It Works
An ARM Warehouse Robot operates through a mix of hardware and software. Sensors detect the location of objects and obstacles. Motors move the arm and joints. Computer algorithms plan the path and control the motion. The gripper picks up and places items with care. These robots connect with warehouse management systems. This integration allows them to receive picking and packing instructions, track inventory, and update order status in real time.
Automated picking systems use ARM Warehouse Robots, sensors, and software to boost order volume and reduce mistakes. Robots work with conveyors and packing stations to move goods efficiently. This setup cuts down on manual labor and increases throughput.
Applications
Warehouses use ARM Warehouse Robots for many tasks:
Picking items from shelves or bins.
Packing products into boxes.
Sorting goods by order or destination.
Palletizing and depalletizing items.
Robotic arms equipped with vision systems and machine learning improve precision and speed. They handle delicate items and a wide range of products. These robots reduce manual labor, increase order accuracy, and help workers focus on higher-value jobs. ARM Warehouse Robots also lower costs by reducing errors and product damage. They make warehouses safer by taking on repetitive or hazardous tasks. Many companies use ARM Warehouse Robots alongside AMRs and AGVs to create flexible and efficient workflows.
Palletizing and Depalletizing Robots
Palletizers
Palletizing robots help warehouses stack products onto pallets quickly and accurately. These robots use sensors and vision systems to recognize products and pick them up from conveyors. They arrange items in stable layers and stack them on pallets with precision. This process improves the speed and quality of warehouse operations.
Palletizing robots start by recognizing and orienting products using cameras or sensors.
Robotic arms pick up products securely from moving lines.
The robots form layers by arranging products in patterns that keep stacks stable.
Each layer is placed on the pallet, building up the stack one level at a time.
Palletizing robots work nonstop, which increases throughput and supports just-in-time inventory.
Automation reduces workplace injuries by handling heavy lifting and repetitive tasks.
Consistent stacking lowers the risk of product damage and improves warehouse flow.
These robots can handle different product sizes, making them flexible for many operations.
Over time, companies save money on labor and product loss.
Palletizing robots can double or even triple the speed of manual stacking. Some warehouses have seen throughput increase by 150% after installing these systems. Robots also help companies redeploy workers to higher-value jobs, making the whole operation more efficient.
Depalletizers
Depalletizing robots remove products from pallets and prepare them for storage or shipping. These robots use sensors to identify items and robotic arms to lift them safely. They work with many types of products, from boxes to bags.
Logistics workers often face injuries from lifting, repetitive motions, and slips. Depalletizing robots reduce these risks by taking over the most dangerous tasks. Automation removes workers from hazardous activities, which lowers injury rates and helps companies meet safety standards. Surveys show that warehouse workers feel more optimistic about safety when robots handle heavy lifting and repetitive jobs.
By automating depalletizing, warehouses create safer environments and reduce costs linked to workplace injuries. This shift also helps companies follow safety rules and protect their teams.
Conveyor and Sorting Systems
Conveyor Systems
Conveyor systems move products through warehouses automatically. These systems use belts, rollers, or chains to carry items from one area to another. Many warehouses use conveyors to connect storage, picking, packing, and shipping zones. This setup reduces the need for workers to move items by hand.
Conveyor systems automate material movement, which lowers manual labor and improves accuracy.
They work well with other automation tools, such as sorting robots and robotic arms, to create smooth workflows.
Warehouses see higher productivity, lower labor costs, and better safety when using conveyors.
These systems help increase order fulfillment speed and accuracy.
Key performance indicators for conveyors include throughput, order speed, accuracy, and operational efficiency.
Choosing the right conveyor depends on how much the warehouse handles, the size and weight of items, and how well the system can grow with the business.
Proper installation and regular maintenance keep conveyors running smoothly and extend their lifespan.
Conveyor systems play a key role in warehouse automation. They help companies save money and deliver orders faster.
Sorting Robots
Sorting robots organize products by order, size, or destination. These robots use sensors, cameras, and artificial intelligence to identify and sort items quickly. They work with conveyor systems to move products to the right place.
Robot Type | Key Features | How It Improves Order Accuracy |
|---|---|---|
Grid-based ground marker robot | AI-driven, uses sensors and grid markers, sorts up to 30,000 items/hour | Removes human error, ensures precise sorting, enables highly accurate order fulfillment |
Vertical sortation robot | Operates on tracks at different heights, AI-enabled, maximizes space | Scalable, reduces errors, improves accuracy in space-limited warehouses |
Uses vision systems and robotic arms, handles multiple orders at once | Reduces picking and packing mistakes, improves packaging and order accuracy |
Sorting robots work nonstop and do not get tired. They update inventory in real time and help warehouses keep track of every item. By using advanced technology, these robots reduce mistakes and speed up order processing. They also adapt to different product types and packaging needs, making them useful for many warehouse operations.
Sorting robots help warehouses deliver the right products to customers quickly and accurately.
Packing Robots
Packing Robots
Packing robots play a key role in modern warehouses. These robots handle many tasks that once required manual labor. They fill boxes, wrap products, seal packages, apply labels, and sort items for shipping. Some systems even load and stack boxes onto pallets. Packing robots work with advanced sensors and vision systems. These technologies help robots detect errors, such as misaligned labels or broken seals, in real time. Robots can correct mistakes quickly, which keeps packaging quality high.
Packing robots do not get tired or slow down. They keep a steady pace all day, which increases packaging speed and throughput compared to manual work.
Many warehouses use packing robots to support different product lines. Modern robots can switch between packaging formats with little downtime. This flexibility helps companies meet changing customer demands. Packing robots also help reduce product waste by keeping fill levels and seals consistent.
Packing robots perform tasks such as:
Filling boxes and containers
Wrapping and sealing packages
Labeling products
Sorting and loading items
Stacking and palletizing boxes
These robots use:
Optical sensors and vision systems for precision
Machine learning and AI to detect and fix defects
Automated feeding systems to speed up the process
Packing robots improve safety by taking over repetitive and heavy tasks. Workers face fewer injuries and can focus on higher-value jobs. Automation also helps companies follow safety rules and reduce operating costs.
Packing robots can boost packaging output by up to 30%. Vision inspection systems lower product defects by 25-30%. Automation in packing and palletizing can improve throughput by up to 50% and cut labor needs. Many warehouses see productivity rise by 22% each year after adding packing robots. Operating expenses and labor costs also drop by up to 20%.
Automated Storage and Retrieval
AS/RS
Automated Storage and Retrieval Systems (AS/RS) help warehouses store and retrieve items with high efficiency. These systems use machines and software to move products in and out of storage locations. AS/RS connects with warehouse management systems to keep track of inventory and orders. Many warehouses choose AS/RS because it saves space and improves accuracy.
AS/RS systems automate storage and retrieval tasks, working closely with warehouse management software.
They use both vertical and horizontal space, allowing warehouses to store more items in the same area.
Manual storage needs wide aisles and more floor space, but AS/RS can use tall racks and compact layouts.
These systems increase storage density and reduce the need for manual handling.
AS/RS improves order speed, accuracy, and safety for workers.
Warehouses can scale operations easily by adding more AS/RS units.
The first AS/RS systems showed that tall facilities could store millions of items, saving space and reducing labor.
AS/RS systems help warehouses handle more products without needing bigger buildings. They also make it easier to find and move items quickly, which helps companies fill orders faster and with fewer mistakes.
Static Robots
Static robots play a key role in warehouse automation. These robots stay in one place and perform tasks like packing, sorting, or stacking products. Companies often use static robots for jobs that need speed and accuracy.
Aspect | Description |
|---|---|
Definition | Static robots are fixed robotic arms installed in a specific location within the warehouse. They perform tasks such as packing, sorting, and palletisation. |
Advantages | - Adaptability: Can be reprogrammed to handle changes in warehouse needs (e.g., product lines, pallet shapes). |
Limitations | - Impact on operations: Require warehouse layout reconfiguration causing downtime and inefficiencies. |
Static robots can adapt to new products or tasks by changing their programming. They work well with other automated systems and help boost productivity. However, installing static robots may require changes to the warehouse layout. This process can cause downtime and reduce flexibility. Static robots work best in settings where tasks do not change often and high speed is important.
Drones
Inventory Drones
Inventory drones help warehouses track stock quickly and safely. These drones fly through aisles and scan barcodes or QR codes on products and shelves. They reach high racks that people cannot access easily. Drones like the Corvus One use artificial intelligence and high-resolution cameras to perform full inventory checks every week. This happens much more often than manual counts, which usually take place only once a quarter or year. Frequent checks increase inventory accuracy and give managers near real-time updates. This helps warehouses fulfill orders faster and manage resources better.
Drones replace slow and risky manual counting. Workers do not need to climb ladders or use lifts, which lowers the chance of accidents. Drones also reduce human error and keep aisles clear, making the warehouse safer. Some drones, such as the Flybox prototype, connect to automated warehouse trucks. They use sensors and geo-navigation to scan barcodes and take photos of pallets with great precision. These drones send data directly to inventory management software, which improves accuracy and reduces mistakes. Many companies have tested these systems and found them effective for real warehouse use.
Monitoring Drones
Monitoring drones support warehouse safety and efficiency in several ways:
Scan inventory, perform stocktaking, and help with picking using cameras and sensors.
Eliminate the need for workers to use ladders or forklifts to reach high shelves, reducing accident risks.
Operate autonomously, which keeps people away from dangerous areas.
Deliver tools and spare parts quickly within the warehouse.
Inspect high or hard-to-reach places and monitor for theft or unsafe behavior.
Drones help avoid collisions in busy warehouses by using smart navigation. They often work outside normal hours, which limits human exposure to hazards. By taking over risky or repetitive tasks, drones make warehouses safer and more efficient.
Collaborative Robots
Cobots
Collaborative robots, or cobots, work directly with human workers in warehouse environments. These machines help with repetitive, physically demanding, or hazardous tasks. Cobots use advanced sensors and vision systems to detect people and objects, which helps them avoid collisions and respond safely to human presence.
Cobots perform tasks such as picking, packing, palletizing, and inventory management.
They operate with consistent speed and precision, which reduces errors and increases productivity.
Workers can guide cobots by hand or use simple controls, making them easy to reprogram and redeploy.
Cobots fit into existing warehouse layouts without major changes, offering flexibility for different operations.
Safety features include speed and separation monitoring, power and force limiting, and automatic stops when people come close.
Cobots do not replace human workers. Instead, they support teams by taking over tedious or dangerous jobs. This allows people to focus on higher-value activities like problem-solving and decision-making. Cobots also help reduce physical strain and injury risk, which improves worker wellbeing and morale. Many workers report feeling more satisfied and confident in their jobs when cobots handle the most demanding tasks.
Cobots create safer, more inclusive workplaces by fostering teamwork between humans and machines.
Research shows that cobots boost warehouse productivity by automating material handling and inventory tasks. Their precise control systems maximize throughput and operational efficiency. Human-cobot interfaces allow workers to monitor and adjust robot actions easily, which reduces mistakes and supports smooth collaboration. As cobots take on manual labor, workers can shift to more complex roles, often leading to greater job fulfillment. Training and workspace redesign help ensure safe and effective cooperation.
Cobots offer a rapid return on investment, especially during labor shortages. Their flexibility, safety, and ability to work around the clock make them valuable assets in modern warehouses.
Warehouse robots such as AGVs, AMRs, ARM Warehouse Robot, drones, and cobots each play a unique role in modern warehouses. These technologies automate repetitive tasks, improve accuracy with real-time tracking, and enhance safety by handling hazardous jobs.
Robots optimize space, streamline operations, and reduce errors.
Integration with warehouse management systems boosts efficiency.
Companies should assess their needs to select the right mix of robots for their operations.
FAQ
What is the difference between AGVs and AMRs?
AGVs follow fixed paths using wires or markers. AMRs use sensors and maps to move freely. AGVs work best in simple layouts. AMRs handle busy or changing spaces.
How do warehouse robots improve safety?
Warehouse robots take over dangerous tasks. They lift heavy items and work in risky areas. This reduces injuries and keeps workers safe.
Can robots work with people in the warehouse?
Yes. Cobots, or collaborative robots, work side by side with people. They use sensors to avoid accidents and help with picking, packing, and sorting.
Are warehouse robots hard to install?
Some robots, like AGVs, need changes to the warehouse layout. Others, such as AMRs and cobots, install quickly and fit into most spaces with little setup.
Do robots replace human workers?
Robots handle repetitive or risky jobs. People focus on planning, problem-solving, and quality checks. Robots support workers and help them do their jobs better.
