For years, opportunistic charging has been the go-to solution for AGV and AMR fleets looking to minimize downtime. The idea is simple – robots charge whenever they have a few minutes to spare. It sounds efficient. It sounds logical. It even sounds like the future.
But is it?
If opportunistic charging is the answer, why are so many warehouses still over-purchasing AGVs to compensate for downtime? Why do automation managers still worry about whether their fleet will last through a full shift? Why do charging stations still dictate workflows instead of the other way around?
The Real Question: Where Does Charging Actually Belong?
The conversation about when AGVs charge has dominated automation strategy for years. But a far more important question has been overlooked – where should they charge?
Most facilities still rely on fixed, designated areas for energy transfer, whether it’s traditional plug-in stations or inductive pads that require precise alignment. Even opportunistic models are constrained by where a robot finds its charge – a break in the action, a side station, a moment of downtime.
But the real-world movements of an AGV fleet aren’t dictated by convenient breaks. Charging should adapt to operations, not the other way around.
The Unseen Cost of Chasing Power
When energy isn’t available at the right place, fleets compensate in ways that aren’t immediately obvious:
- Running more AGVs than necessary, just to offset downtime
- Allowing workarounds that create inefficiencies in warehouse flow
- Accepting that “some downtime” is just the cost of automation
It’s a familiar tradeoff, but one that doesn’t need to exist.
100% Fleet Utilization – What’s Holding It Back?
The best-performing AGV fleets don’t waste time seeking power – they receive power where it naturally fits into their operation. That means no special stops, no parking, no unnecessary detours.
Static charging stations create bottlenecks. Opportunistic charging offers flexibility, but still operates within a constraint that doesn’t need to exist anymore.
Power-in-Motion technology is already reshaping how automation leaders think about fleet efficiency. The biggest adopters of AGVs aren’t investing in more robots – they’re ensuring that the robots they have are always running.
If You Were Starting From Scratch Today…
Would you design an automated facility that still had charging downtime? Would you accept an energy strategy that required AGVs to deviate from their tasks just to stay operational?
Or would you build a system where energy is exactly where it’s needed – when it’s needed – without disrupting anything else?
Some warehouses are already making that shift. The good news? It’s not too late to catch up.
Power-in-Motion technology isn’t just for new fleets- it can be retrofitted into existing AGVs and AMRs, transforming operations overnight. No need to overhaul infrastructure, no need for expensive fleet expansion- just in-motion power that eliminates downtime instantly.
The question isn’t if the industry will move beyond opportunistic charging. It’s how soon.
