{"id":21866,"date":"2026-07-14T13:58:23","date_gmt":"2026-07-14T11:58:23","guid":{"rendered":"https:\/\/www.robox.it\/?p=21866"},"modified":"2026-07-14T13:58:23","modified_gmt":"2026-07-14T11:58:23","slug":"robox-agv-and-plant-simulation-the-value-of-the-digital-twin-in-design","status":"publish","type":"post","link":"https:\/\/www.robox.it\/en\/robox-agv-and-plant-simulation-the-value-of-the-digital-twin-in-design\/","title":{"rendered":"Robox AGV and plant simulation: the value of the Digital Twin in design"},"content":{"rendered":"<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_89 ez-toc-wrap-center counter-hierarchy ez-toc-counter ez-toc-grey ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\"><\/p>\n<span class=\"ez-toc-title-toggle\"><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1 ' ><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/www.robox.it\/en\/robox-agv-and-plant-simulation-the-value-of-the-digital-twin-in-design\/#Configure_virtual_AGVs_with_real_parameters\" >Configure virtual AGVs with real parameters<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/www.robox.it\/en\/robox-agv-and-plant-simulation-the-value-of-the-digital-twin-in-design\/#The_digital_map_of_the_plant\" >The digital map of the plant<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/www.robox.it\/en\/robox-agv-and-plant-simulation-the-value-of-the-digital-twin-in-design\/#AGV_Manager_fleet_management_and_communications\" >AGV Manager: fleet management and communications<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/www.robox.it\/en\/robox-agv-and-plant-simulation-the-value-of-the-digital-twin-in-design\/#Plant_logic_and_mission_assignment\" >Plant logic and mission assignment<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-5\" href=\"https:\/\/www.robox.it\/en\/robox-agv-and-plant-simulation-the-value-of-the-digital-twin-in-design\/#An_application_case_in_the_textile_industry\" >An application case in the textile industry<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-6\" href=\"https:\/\/www.robox.it\/en\/robox-agv-and-plant-simulation-the-value-of-the-digital-twin-in-design\/#Simulation_also_in_the_RDE_environment\" >Simulation also in the RDE environment<\/a><\/li><\/ul><\/nav><\/div>\n\n<p class=\"wp-block-paragraph\">When it comes to <strong>AGVs<\/strong> (Automatic Guided Vehicles), the main question that arises in every plant is how many vehicles are required to meet demand and perform all assigned tasks. Defining this number can be challenging, as many factors may have an impact: from AGV performance, such as speed and acceleration, through to the size of the plant and the characteristics of the traffic routes available. All these data can be assessed in the best possible way through a <strong>digital plant simulation<\/strong>, i.e. by emulating the system production times and the AGVs on a computer using the <strong>Digital Twin<\/strong>.  <\/p>\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Configure_virtual_AGVs_with_real_parameters\"><\/span>Configure virtual AGVs with real parameters<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<p class=\"wp-block-paragraph\">The emulated AGVs can be configured exactly like the real ones by setting the same parameters, including:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>velocit\u00e0,<\/li>\n\n\n\n<li>acceleration,<\/li>\n\n\n\n<li>jerk,<\/li>\n\n\n\n<li>maximum rotation speed. <\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">In this way, the travel time of the emulated AGVs will reflect that of the real vehicles in the final plant, allowing the cycle time to be calculated.<br\/><\/p>\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"The_digital_map_of_the_plant\"><\/span>The digital map of the plant<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<p class=\"wp-block-paragraph\">Another useful element to develop is the plant map, which allows the system operation to be simulated and tested even when the building housing the actual plant is still under construction.<\/p>\n\n<p class=\"wp-block-paragraph\">This makes it possible to significantly optimize the program development and debugging times. No on-site surveys are required; a DXF file containing the project to be imported into the <a href=\"https:\/\/www.robox.it\/en\/product\/robox-agv-tool-rat\/\" data-type=\"product\" data-id=\"3109\" target=\"_blank\" rel=\"noreferrer noopener\">RAT (Robox AGV Tool)<\/a> is sufficient. The RAT is the small CAD tool provided by the Robox environment and allows the map to be designed and drawn with:  <\/p>\n\n<ul class=\"wp-block-list\">\n<li>AGV lanes,<\/li>\n\n\n\n<li>curves,<\/li>\n\n\n\n<li>workstations.<\/li>\n<\/ul>\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"AGV_Manager_fleet_management_and_communications\"><\/span>AGV Manager: fleet management and communications<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<p class=\"wp-block-paragraph\">The map is then loaded into the fleet manager, the Robox <a href=\"https:\/\/www.robox.it\/en\/product\/agv-manager-agv_manager\/\" data-type=\"product\" data-id=\"2847\" target=\"_blank\" rel=\"noreferrer noopener\">AGV Manager<\/a>. <\/p>\n\n<p class=\"wp-block-paragraph\">This tool enables communication with the AGVs and with the plant systems, managing different levels of integration.<\/p>\n\n<p class=\"wp-block-paragraph\">AGV Manager enables communication with the AGVs via:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>radio modem with serial connection,<\/li>\n\n\n\n<li>wireless LAN with TCP\/IP protocol,<\/li>\n\n\n\n<li>wireless LAN with UDP protocol.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\"><strong>Communication with the plant PLCs<\/strong> via:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>RS232 serial interface,<\/li>\n\n\n\n<li>OPC server,<\/li>\n\n\n\n<li>Ethernet with send\/receive protocol,<\/li>\n\n\n\n<li>Ethernet with fetch\/write protocol,<\/li>\n\n\n\n<li>generic file reading and writing.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">AGV Manager also supports <strong>communication with databases<\/strong>, including:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>SQL Server,<\/li>\n\n\n\n<li>MySQLm<\/li>\n\n\n\n<li>PostgreSQL,<\/li>\n\n\n\n<li>ODBC.<\/li>\n<\/ul>\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Plant_logic_and_mission_assignment\"><\/span>Plant logic and mission assignment<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<p class=\"wp-block-paragraph\">The Robox <strong>Fleet Manager<\/strong> allows the developer to describe the plant logic and the assignment of missions to the vehicles in text format (x-script), together with the management of input\/output signals with the plant PLC.<\/p>\n\n<p class=\"wp-block-paragraph\">In addition to all this, the true major advantage of <a href=\"https:\/\/www.robox.it\/en\/product\/agv-manager-agv_manager\/\" data-type=\"product\" data-id=\"2847\" target=\"_blank\" rel=\"noreferrer noopener\">AGV Manager<\/a> lies in its <strong>autonomous navigation management<\/strong>, which requires no intervention by the developer or installer. The manager follows the same logic as the highway code, controlling: <\/p>\n\n<ul class=\"wp-block-list\">\n<li>vehicle priority rules,<\/li>\n\n\n\n<li>queuing,<\/li>\n\n\n\n<li>one-way routes,<\/li>\n\n\n\n<li>traffic lights.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">This allows the fleet behavior within the plant to be simulated and managed realistically.<\/p>\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"An_application_case_in_the_textile_industry\"><\/span>An application case in the textile industry<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<p class=\"wp-block-paragraph\">In 2019, a large company operating in the textile industry commissioned Robox to design an AGV system to manage the loading of finished products from the winding machines and unloading at the storage and warehousing stations. The AGVs used the <a href=\"https:\/\/www.robox.it\/en\/product\/rp-2-as1018-002-as1018-003-as1018-012\/\" data-type=\"product\" data-id=\"15589\" target=\"_blank\" rel=\"noreferrer noopener\">RP-2<\/a> controller to manage their 9 axes and adopted <strong>Robox inertial navigation<\/strong> (see <a href=\"https:\/\/www.robox.it\/en\/products\/agv-automatic-guided-vehicle\/\" data-type=\"page\" data-id=\"19463\" target=\"_blank\" rel=\"noreferrer noopener\">Navigation Systems for AGVs<\/a>). <\/p>\n\n<p class=\"wp-block-paragraph\">The designer followed the steps listed above, requiring:<\/p>\n\n<ul class=\"wp-block-list\">\n<li>the drawing of the plant under construction,<\/li>\n\n\n\n<li>the number of reels that would be produced,<\/li>\n\n\n\n<li>the different characteristics of the various production lines,<\/li>\n\n\n\n<li>the rules to be followed for unloading management.<\/li>\n<\/ul>\n\n<h3 class=\"wp-block-heading\">AGV fleet simulation<\/h3>\n\n<p class=\"wp-block-paragraph\">Once the map had been drawn, the technician started the <a href=\"https:\/\/www.robox.it\/en\/product\/agv-manager-agv_manager\/\" data-type=\"product\" data-id=\"2847\" target=\"_blank\" rel=\"noreferrer noopener\">AGV Manager<\/a> and set the kinematic parameters of the individual AGV, then instantiated several vehicles of the same type with the same characteristics. In order to correctly simulate the cycle, the various timings were required, including: <\/p>\n\n<ul class=\"wp-block-list\">\n<li>the time required to enable unloading from the winding machines,<\/li>\n\n\n\n<li>the battery charging time of the vehicles,<\/li>\n\n\n\n<li>pickup times,<\/li>\n\n\n\n<li>deposit times.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">The simulation with the virtualized AGVs started with a fleet of 20 AGVs.<\/p>\n\n<p class=\"wp-block-paragraph\">After the initial tests, it immediately became clear that this number was insufficient; furthermore, some of the one-way routes selected during plant design did not allow good vehicle mobility, forcing the AGVs headed towards the pickup area to take a long detour that was unsustainable in terms of timing.<\/p>\n\n<h3 class=\"wp-block-heading\">Map and AGV fleet size optimization<\/h3>\n\n<p class=\"wp-block-paragraph\">La mappa \u00e8 stata quindi modificata, cambiando i sensi unici di alcune linee di transito. Anche il numero di AGV \u00e8 aumentato. Le nuove simulazioni hanno dato esito positivo, dimostrando che 26 veicoli erano sufficienti per gestire tutto l\u2019impianto e sostenere il rateo di produzione.<br\/>Considerando la manutenzione ordinaria dei veicoli e gli imprevisti che potrebbero ridurre il numero di AGV realmente operativi, alla fine son stati adottati altri due veicoli, in modo da operare normalmente con una mole lavorativa ottimale senza rischiare di andare in sovraccarico nel caso di uno o anche due veicoli fermi.  <br\/><\/p>\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Simulation_also_in_the_RDE_environment\"><\/span>Simulation also in the RDE environment<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n<p class=\"wp-block-paragraph\">In addition to AGV Manager, simulation is also possible within the <a href=\"https:\/\/www.robox.it\/en\/product\/rde-robox-development-environment\/\" data-type=\"product\" data-id=\"15578\" target=\"_blank\" rel=\"noreferrer noopener\">RDE (Robox Development Environment)<\/a>, allowing system logic, movements, and interactions to be verified directly during the development phase, without the need for an <a href=\"https:\/\/www.robox.it\/en\/products\/pac-programmable-motion-controllers\/\" data-type=\"page\" data-id=\"15994\" target=\"_blank\" rel=\"noreferrer noopener\">RP-family<\/a> controller on the desk: a PC is all that is required.<\/p>\n\n<p class=\"wp-block-paragraph\">Since this feature was implemented, it has helped technicians from various users of the Robox system to simulate the axes of their machines in order to predict the behavior of the future real applications. In this way, it is possible to: <\/p>\n\n<ul class=\"wp-block-list\">\n<li>test the cycles,<\/li>\n\n\n\n<li>debug the programs,<\/li>\n\n\n\n<li>calculate the plant cycle times.<\/li>\n<\/ul>\n\n<p class=\"wp-block-paragraph\">This feature is useful for every type of user, considering that the Robox system is adopted by companies operating in many sectors, including robotics, packaging and beverage, CNC machines, and laser cutting.<\/p>\n\n<hr class=\"wp-block-separator has-alpha-channel-opacity\"\/>\n\n<div class=\"wp-block-media-text is-stacked-on-mobile\"><figure class=\"wp-block-media-text__media\"><img decoding=\"async\" width=\"1030\" height=\"789\" src=\"https:\/\/www.robox.it\/wp-content\/uploads\/marco-bassignana-1030x789.webp\" alt=\"marco bassignana\" class=\"wp-image-21855 size-full\" srcset=\"https:\/\/www.robox.it\/wp-content\/uploads\/marco-bassignana-1030x789.webp 1030w, https:\/\/www.robox.it\/wp-content\/uploads\/marco-bassignana-300x230.webp 300w, https:\/\/www.robox.it\/wp-content\/uploads\/marco-bassignana-768x588.webp 768w, https:\/\/www.robox.it\/wp-content\/uploads\/marco-bassignana-1536x1176.webp 1536w, https:\/\/www.robox.it\/wp-content\/uploads\/marco-bassignana-2048x1568.webp 2048w, https:\/\/www.robox.it\/wp-content\/uploads\/marco-bassignana-1500x1148.webp 1500w, https:\/\/www.robox.it\/wp-content\/uploads\/marco-bassignana-705x540.webp 705w, https:\/\/www.robox.it\/wp-content\/uploads\/marco-bassignana-450x345.webp 450w, https:\/\/www.robox.it\/wp-content\/uploads\/marco-bassignana-800x612.webp 800w\" sizes=\"(max-width: 1030px) 100vw, 1030px\" \/><\/figure><div class=\"wp-block-media-text__content\">\n<p class=\"wp-block-paragraph\">The development of this plant was handled by <strong>Marco Walter Bassignana<\/strong>, Project Manager at Robox S.p.A., who holds a degree in Mechatronics from the Polytechnic University of Turin and has over ten years of experience in developing customer applications, installing systems, and training new internal and external technicians entering the Robox world.<\/p>\n<\/div><\/div>\n","protected":false},"excerpt":{"rendered":"<p>Digital simulation allows virtual AGVs to be configured, cycle times to be evaluated, plant layouts to be optimized, and the number of vehicles required to be verified before commissioning.<\/p>\n","protected":false},"author":16,"featured_media":21864,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"%%post_title%% %%sep%% %%sitetitle%%","_seopress_titles_desc":"La simulazione digitale consente di configurare AGV virtuali, valutare tempi ciclo, ottimizzare mappe d\u2019impianto e verificare il numero di veicoli necessari prima della messa in 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