AGV Racking Compatibility

Rack System Compatibility by AGV Type

Rack System	Compatible AGV Types	Notes
Selective pallet rack	All AGV types	Most common integration; laser or floor-marker guidance
Double-deep selective	Reach truck AGV	100% selectivity at 2 pallets deep
Pallet flow rack	Unit load AGV, reach truck AGV	FIFO; lane length adds 12-24 in. for separators
Push-back (cart)	Reach truck AGV	2-7 deep LIFO
Drive-in / drive-thru	Counterbalanced forklift AGV	Rare; requires precise guidance in enclosed rack
VNA rack	VNA AGV only	Wire or rail guidance in aisle required
Cantilever	Specialized AGV (ANSI MH16.3)	Custom interface; reference MH16.3 for design

Structural Requirements for AGV-Compatible Racking

Underride AGV Considerations

Standard hook-and-slot beam connections can fail under upward lifting forces from underride AGVs. AGV-compatible racks require:

• Rigid bolted frame: All beams, braces, and shelves bolted with Grade 8.8+ high-strength bolts and serrated anti-loosening nuts
• Upward force rated: Rack must be engineered for the lift force of the AGV’s mechanism, not just downward gravity loads

Structural Condition Requirements

Rack must be free of:

• Bowing, sagging, or leaning uprights or beams (interferes with laser sensor detection)
• Damaged or repaired sections that create dimensional inconsistency
• Any overloaded bays that deflect beams out of tolerance

Clearance Specifications

Horizontal Clearances (Load to Upright)

• Minimum 3 inches (76mm) between the inside edge of the upright and the widest point of the pallet or load
• AGV tolerance is tighter than manned equipment: recommend increasing to 4-6 inches (100-150mm) for AGV positioning systems with ±10-25mm accuracy (SLAM)
• For laser-guided AGVs (±5mm accuracy): 3 inches may be sufficient with confirmed positional repeatability

Vertical Clearances

• Minimum vertical clearance above loaded pallet to next beam: 3-4 inches (75-100mm) standard; increase for AGV approach speed and sensor field
• Cross-aisle clearance: minimum 2% of top beam height (e.g., 20 ft top beam = 4.8 in clearance)
• Down-aisle clearance: minimum 5% of top beam height (e.g., 20 ft top beam = 12 in clearance)

Pallet Flow Lane Additions

Add 12-24 inches of lane length per bay to accommodate pallet separators and AGV stop positions.

Interface and Docking Requirements

• Access pocket locations must be consistent throughout the rack — position variance between bays defeats AGV repeatability
• Access pockets must be evenly distributed and accessible from the AGV approach direction
• Recommend device-agnostic docking interfaces (universal pocket dimensions) to avoid vendor lock-in
• Confirm pocket height matches AGV fork height at approach (loaded vs. empty fork height differential)

Upright Protection

In AGV environments, upright protectors serve two purposes: physical protection and as a reference datum for sensor calibration. Requirements:

• Protectors must not protrude into the aisle beyond the upright face
• Must withstand repeated low-speed AGV contact (typical AGV bumper speed: 0.3 m/s)
• Do not install protectors that change the reflectivity pattern visible to laser scanners

Compatible Guidance Methods by Rack Type

Rack Environment	Typical Guidance
Open selective aisles	Laser triangulation or natural SLAM
VNA rack aisles	Wire guidance or rail (no room for laser correction)
Drive-in rack	Wire guidance only
End-of-aisle transfer	Floor magnetic spots or laser

RMI and Standards Reference

• ANSI MH16.1: Standard for steel selective pallet rack (RMI)
• ANSI MH16.3: Cantilever rack design
• ANSI/ITSDF B56.5-2024: AGV safety, guidepath clearance requirements
• ISO 3691-4:2023: Driverless truck safety, restricted zone definitions