Project Overview
Manufacturing and Heavy Transport
Movement and indexing of buses between assembly stations
Ultra-thin top-load AGV (Automated Guided Vehicle) with integrated lifting and 360° LIDAR safety
The Challenge
Microbird’s Ecotuned Division converts thermal-engine buses into 100% electric buses. This process involves multiple parallel assembly stations. During critical stages of the conversion:
- The thermal engine is removed.
- Propulsion systems become inoperable.
- The bus can no longer move under its own power.
The company needed a solution to index and move buses from one station to another quickly and safely, despite the lack of propulsion.
Current Solutions
Traditional towing or handling methods presented several constraints:
- Complex maneuvers in confined spaces.
- Increased risks for operators.
- High movement time.
- Difficulty optimizing space between bays.
The need was clear: a flexible, secure, and perfectly adapted solution for the electric conversion context.
ProjectObjectives
Safety was a top priority for Microbird, particularly during the critical phases of the conversion process. Traditional methods of moving buses—such as manual towing or handling—posed significant risks to operators due to the size and weight of the vehicles. The lack of propulsion during conversion made these maneuvers even more hazardous.
Time efficiency is a critical factor in manufacturing, especially in a process as complex as converting buses from thermal to electric propulsion. Delays in moving buses between assembly stations could create bottlenecks, slow down production, and increase operational costs.
In traditional manufacturing setups, wide circulation aisles are often required to accommodate the movement of large vehicles like buses. However, these aisles take up valuable floor space, reducing the overall efficiency of the production layout.
Microbird wanted to optimize space utilization by minimizing the need for large aisles. The goal was to design a system that could maneuver buses laterally and precisely, eliminating the need for extensive turning radii or additional space for manual handling. By reducing the space dedicated to circulation, Microbird aimed to maximize the use of available floor space for assembly stations, tools, and equipment, ultimately enhancing the density and efficiency of the production line.
A well-organized production layout is essential for maintaining efficiency and scalability in manufacturing. Microbird recognized that the traditional layout, with its wide aisles and manual handling processes, was not fully optimized for the electric conversion process.
Efficiency in assembly flow is critical to maintaining high productivity and quality standards. Microbird sought to enhance the entire assembly process by ensuring that buses moved seamlessly from one station to the next without unnecessary delays or disruptions.
See it in action
Omnidirectional AGV / Heavy-Duty Bus-Handling
The developed solution
INOGEC designed a custom ultra-thin platform AGV, specifically developed for this application.
01
Specialized Mechanical Design
- Platform thin enough to slide under the bus.
- Automatic centering system under the chassis.
- Custom lifting tool.
- Gripping at strategic lifting points on the chassis.
The robot positions itself precisely under the vehicle, aligns automatically, and lifts the bus safely w
02
Advanced 360° Safety
Once the bus is lifted:
- LIDAR sensors create a complete protection zone around the vehicle.
- Real-time obstacle detection.
- Secure movements under operator supervision.
03
Omnidirectional Movement
Since the assembly bays are arranged in parallel, the main challenge was the lateral movement of the buses. The AGV vehicle was designed to perform: Controlled lateral movement ("crab movement")
This allows:
- Moving the bus directly from one station to another.
- Eliminating the need for large circulation aisles.
- Avoiding complex rotation maneuvers.
Optimization of Production Layout
One of the major impacts of the project was the optimization of manufacturing space.
Thanks to the lateral movement capability:
- Reduction of inter-station spaces.
- Densification of assembly bays.
- Maximization of every square foot.
- Improved linear flow efficiency.
The AGV technology didn’t just enable transportation; it allowed rethinking the organization of the production space.
The Result
The solution enabled:
- Significant acceleration of indexing sequences.
- Reduction of risks associated with manual maneuvers.
- Increased operator safety.
- Optimization of layout and better space utilization.
- Standardization of the movement process.
Microbird now has a reliable and reproducible system for safely moving non-functional buses throughout the electric conversion process.
AGV selected
Platform series
With up to 200 000 lbs payload, you can optimise your production with precise motion, customizability and high reliability to make sure your production never stop.
Payload lifting capacity
Up to 40 000 lbs
Payload towing capacity
Up to 200 000 lbs
Average footprint
120'' x 56" x 12"
Integrated lifting device
Up to 20" stroke
