Case Study
ABB Robotics AMRs at the Core of the Autonomous Automotive Factory
An executive product catalog by ABB Robotics detailing Autonomous Mobile Robots (AMRs) engineered to automate intralogistics and drive the transition toward 24/7 "dark factories" in automotive manufacturing.Featuring AI-powered Visual SLAM 3D vision navigation and the AMR Studio® software suite, it showcases modular tugs, movers, and stackers designed to overcome labor shortages and boost operational flexibility. Discover how ABB Robotics' Visual SLAM technology and modular AMR portfolio streamline intralogistics, resolve labor shortages, and accelerate the path to 24/7 dark factories.
- Topic
- Hardware
- Published
- 27 Oct 2026
The automotive industry faces severe labor shortages, rising operational costs, and increasing customization demands that render traditional fixed conveyor systems obsolete. ABB Robotics introduces a complete ecosystem of Autonomous Mobile Robots (AMRs) designed to automate material handling, connecting production cells and storage operations without rigid infrastructure.
Powered by Visual SLAM 3D vision, ABB's AMRs use AI and cameras to build dynamic 3D maps and navigate changing plant environments safely alongside personnel. Managed via the intuitive AMR Studio® software suite, the portfolio includes Flexley Tug (towing up to 10 tonnes), Flexley Mover (carrying up to 1,500 kg), and Flexley Stack forklift AMRs, offering automotive manufacturers a scalable, modular path toward fully autonomous "dark factory" operations.
Key Highlights:
Path to the "Dark Factory": Enables 24/7 autonomous plant operations through integrated robotics, AMRs, AI, and remote software monitoring.
AI-Powered Visual SLAM: Uses 3D cameras and AI to build real-time environment maps, recognizing fixed structures while distinguishing moving vehicles and personnel.
Infrastructure-Free Navigation: Eliminates the need for magnetic tape, floor wires, or QR codes, allowing rapid route reconfigurations as plant layouts change.
Flexley Tug Series (AMR T901, T701, T702): Compact tugging AMRs including heavy-duty tractor units capable of towing up to 10 tonnes of trolleys.
Flexley Mover Series (AMR P603, P604): Platform AMRs supporting loads up to 1,500 kg with all-direction mobility for space-constrained line supplies and interprocess flows.
Flexley Stack Series (AMR F712): Counterbalanced forklift AMRs designed for high-capacity pallet/container handling and vertical storage operations.
AMR Studio® Software Suite: Unified software providing fast commissioning, map creation, route definition, and mission configuration across all AMR models.
AMR Studio® Fleet Manager: Server-based traffic and fleet manager offering real-time order allocation, operations visualization, and open APIs for third-party system integration.
Comprehensive 360° Safety Architecture: Meets strict safety standards with laser scanners, safety PLCs, load/fork sensors, warning systems, and emergency stops for collaborative human-robot environments.
Flexible Energy Management: Equipped with high-efficiency Li-Ion batteries supporting both manual battery swapping and automated online charging strategies.
Proven Global Experience: Backed by ABB's global footprint of over 500,000 delivered robot solutions across 53+ countries.