LoadRunner – Highly dynamic robotics for logistics

The “LoadRunner” is a highly dynamic transport system that represents a new generation of automated guided vehicles (AGVs). The vehicles can link together to form larger units, reach speeds of up to 10 m/s, and are suitable for logistics centers and airports. These AGVs combine sorting and conveyor technology with flexible functions, reducing the need for fixed infrastructure while offering high scalability.

Highly dynamic systems and dynamic robotic solutions are becoming increasingly important. These robots are characterized by their ability to execute diverse and complex motion sequences precisely and quickly in a variety of operating environments. In the logistics sector, such highly dynamic robotic systems offer significant potential for increasing speed, efficiency, and throughput.

The LoadRunner addresses the vision of a logistics space with minimal infrastructure – as uncluttered as possible – that can be quickly commissioned, adapted, and dismantled. LoadRunners operate as mobile robots that process and fulfill orders at high throughput. In doing so, they open up application areas that were previously reserved for traditional high-performance sorting and conveyor technology. Thanks to their dynamic capabilities and omnidirectional chassis, the automated guided vehicles are particularly well-suited for sorting and distribution processes with high performance requirements.

The LoadRunner, a prototype developed in-house by Fraunhofer IML, impressively demonstrates the possibilities robots offer today for automation in logistics. Contact our institute for collaboration to turn complex ideas into solutions!

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The LoadRunner is a high-speed vehicle. As a highly dynamic robot with an omnidirectional chassis, it can move freely across the floor and avoid collisions even at high speeds. The vehicles operate without fixed routes, creating a flexible, scalable system in which mobile robots perform transport tasks – from packages to bulky goods.

Facts about the LoadRunner prototype

• Omnidirectional chassis
• Maximum speed: 10 m/s
• Acceleration up to 5 m/s²
• Payload: approx. 30 kg per vehicle
• Camera for localization based on ground features at high speeds
• Load stabilization through highly dynamic alignment based on the acceleration vector
• Magnetic coupling of multiple vehicles or up to four passive trailers

“With the LoadRunner, we are setting a benchmark in the field of highly dynamic mobile transport robots. The high degree of innovation is underscored by the multitude of patents already granted internationally.”
Jan Behling, research associate at Fraunhofer IML in Dortmund

A study on the use of the LoadRunner for package sorting demonstrates the potential of these highly dynamic robots: With just 60 vehicles, it is theoretically possible to sort well over 10,000 shipments per hour. This means the LoadRunner already matches the performance of traditional sorting systems, yet requires significantly less fixed infrastructure and offers:

• faster commissioning of logistics facilities
• dynamic performance adjustment by scaling the number of vehicles
• greater flexibility for layout changes and process adjustments

The simulation is based on a real-time 3D environment that models driving dynamics, localization, and collision avoidance. This allows complex maneuvers to be tested risk-free and the performance of large swarms of mobile robots to be evaluated.

Sorting swarm

In the Sorting Swarm scenario, the LoadRunner functions as a high-speed sorting system for packages or general cargo. The mobile robots:

• move in a swarm at speeds of up to 10 m/s
• navigate freely across the area without a fixed grid
• avoid collisions by adjusting their trajectories and speeds
• transfer cargo using inertia-based braking, without additional actuators

The LoadRunner is thus designed for package distribution centers where flexible, scalable automated guided vehicle systems can supplement or replace traditional sorting systems.

Baggage handling

In the airport baggage handling scenario, LoadRunner vehicles replace or supplement conventional continuous-flow conveyor systems such as conveyor belts. The mobile robots:

• transport and sort pieces of luggage weighing up to 30 kg per vehicle
• navigate freely in buffer areas and transfer zones
• can serve as a buffer by coupling and uncoupling multiple trailers

This creates a flexible, dynamic material flow within the terminal, where autonomous guided vehicles based on the LoadRunner concept meet various load and buffering requirements.

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