Autonomous pallet truck: what it is, and what it isn't

The term gets used a lot, and it covers some very different realities. Here is what an autonomous pallet truck actually does, how it finds its way around, and the most common confusion to clear up before starting any project.

The definition

An autonomous pallet truck is a mobile robot that locates a pallet, aligns itself, engages its forks and sets the pallet down at a defined location. It repeats the motion of a manual or electric pallet truck, removing the trip for the operator. On the robot we deploy, pick-up takes 20 seconds, with a tolerance of 15 cm for an offset pallet and 15° for a rotated one.

What it isn't

An autonomous pallet truck is not a forklift: its lift stays close to the ground (200 mm on the robot, 80 mm with forks lowered) and it does not raise a pallet up into a rack. If your need is stacking at height, this isn't the right machine, and a vendor who sells it to you for that purpose is setting you up for disappointment.

How it finds its way

Earlier generations of automated guided vehicles followed magnetic strips or reflectors installed in the building. Recent machines map the site using 3D LiDAR and cameras: the robot uses dual SLAM, locates itself with no fixed installation at all, detects people and vehicles, and adjusts its path. Manual takeover remains possible at any time.

What your site needs to allow

Feasibility isn't something you read off a spec sheet: it has to be measured. Four measurements determine the answer: thresholds of 10 mm or less, gaps of 35 mm or less, slopes of 3° or less under load, and aisles at least 2 m wide for a 90° pick-up. The site assessment covers these in detail, and the written verdict from the free pre-assessment tells you which ones to check with a ruler.