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Solutions of Integrated Servo Motors in AGVs AMRs

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Customized Integrated Servo Motors For Automated Guided Vehicles (AGV)

—— Changzhou Jkongmotor Co., Ltd   ——
We Design, Engineer, and Manufacture integrated dc servo motors for the AGV & AMR market. We can quickly assemble motor prototypes so that you can start prototyping your new product with minimum downtime. We can start with a few motors and ramp up to 10 million motors if needed, all while providing ongoing product support and confidence that you will get a reliable and consistent product on time and within budget. 
 
integrated servo motors for agv

One-Stop Motion Control Solutions for AGVs / AMRs

Jkongmotor Integrated AGV/AMR All-in-One Drive Unit combines a high-efficiency servo motor, precision planetary gearbox, high-torque drive wheel, and industrial-grade motor driver into a single compact module. Designed specifically for AGV/AMR platforms, this all-in-one solution minimizes wiring, reduces installation complexity, and significantly enhances system reliability and performance.

This integrated design not only simplifies equipment architecture but also improves motion control accuracy, stability, and noise reduction—ideal for modern intelligent logistics, manufacturing automation, and compact robot platforms.

AGV / AMR Designs: Why Integrated Servo Motors for AGVs and AMRs?

As the competitive landscape evolves under the influence of IoT and Industry 4.0, manufacturers are increasingly adopting Automated Guided Vehicles (AGVs), Autonomous Mobile Robots (AMRs), and automated storage systems to secure a market edge; this paper introduces these essential technologies and explores how the specialized features and high-performance characteristics of jkongmotor Integrated servo motors make them the premier choice for modern, high-efficiency drivetrain designs.

 

1. What is the Difference between AGVs and AMRs?

agvs amrs

1.1 AGVs: Fixed Navigation and Predictable Efficiency

Automated Guided Vehicles (AGVs) operate much like a train on invisible tracks, relying on fixed infrastructure such as magnetic tape, wires, or QR codes to navigate. Their primary characteristic is rigid adherence to a predefined path, making them exceptionally reliable for standardized, repetitive tasks in controlled environments. However, their intelligence is limited; if an AGV encounters an obstacle in its lane, it will simply stop and wait for the object to be cleared rather than navigating around it. This makes them best suited for large-scale, stable manufacturing lines where the workflow and layout rarely change.

 

1.2 AMRs: Autonomous Intelligence and Dynamic Flexibility

Autonomous Mobile Robots (AMRs) drive flexible logistics. Equipped with LiDAR, vision sensors, and SLAM, AMRs map, localize, and navigate autonomously without fixed tracks. Their main advantage is high adaptability to dynamic environments: if an aisle is blocked by workers or forklifts, AMRs instantly recalculate and detour to ensure uninterrupted delivery. Furthermore, when production lines change, businesses can redeploy robots within hours simply by updating the digital map software, bypassing physical floor modifications to drastically boost supply chain responsiveness and asset utilization.

 

2. AGV and AMR Structures

2.1 AGV Structure: Guidance-Based Stability

The structure of an Automated Guided Vehicle (AGV) is centered around a robust chassis integrated with specialized guidance sensors designed to follow fixed external paths. Its "nervous system" typically relies on magnetic, optical, or laser-reflecting sensors positioned at the base to detect floor-mounted markers like magnetic tape or QR codes. The drivetrain often utilizes high-torque motors paired with a basic PLC (Programmable Logic Controller) that executes fixed logic—stopping the vehicle immediately via safety bumpers or scanners if an obstacle is detected, as the physical architecture lacks the onboard processing power for autonomous rerouting.

 

2.2 AMR Structure: Autonomous Perception and Intelligence

The structure of an AMR (Autonomous Mobile Robot) integrates advanced autonomous perception and intelligence to navigate dynamic environments. Equipped with sophisticated sensors like LiDAR and cameras, it perceives surroundings in real time, detecting obstacles and mapping paths accurately. This sensory data feeds into intelligent onboard processors running edge AI algorithms, enabling seamless localization, proactive obstacle avoidance, and optimal route planning. By fusing perception with high-level cognitive intelligence, the AMR achieves true operational autonomy and efficiency.

agvs structure

3. What is the Integrated Servo Motor?

An integrated servo motor is a highly cohesive servo "system" that combines a servo motor, an encoder, and a driver into a single unit. Compared to traditional distributed servo motors, the integrated design significantly reduces overall volume and eliminates extensive cabling. This results in a much more compact system that is easy to install, particularly in equipment with severely limited internal space.

 

The drive system is the cornerstone of an Automated Guided Vehicle's (AGV) autonomous navigation. As the core component of this drive system, the integrated servo motor receives commands from the main control system to rotate the wheels, enabling the AGV to move forward, reverse, and steer. Its high precision and rapid dynamic response ensure excellent stability and accuracy throughout the AGV's operation.

 

3.1 Integrated Dc Servo Motor Structure

200w integrated servo motor

3.2 IDC Series Integrated Servo Motor Customization

  • Integrated Servo Motor for AGVs
    Shaft
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    Lead Screw
  • Integrated Servo Motor for AMR
    Module
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    Linear Motion
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    Brake
  • geared Integrated Servo Motor
    Gearbox
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    Worm Gearbox
  • Waterproof Integrated Servo Motor
    Wires
  • IP65 Integrated Servo Motor
    Protect Level
  • IP65 Integrated Servo Motor for
    Protect Level

3.3 IDC Series Integrated Servo Motor Features

● ISO9001/ ISO14001/ CE/ RoHS/ Reach/ CCC...
● Integrated Servo Motors with Gearbox Brake Encoder...
● Planetary Gearbox / Worm Gearbox / Eccentric Gearbox...
● Pulse / RS485 / CANopen / EtherCAT
● IDS42/ IDS57/ IDC60/ IDC80 Series
● 24V / 48V, 26W to 1000W
● IP30, IP54, IP65 Protection Optional
......
 

Integrated Drive Solution for Compact AGVs: A Case Study

Step 1: Requirement Intake & Specification Confirmation

  • Application：Drive system for compact Automated Guided Vehicles (AGVs).
  • Core Component：Integrated servo motor with built-in driver and encoder.
  • Frame Size：NEMA 24.
  • Performance：Peak torque 2 Nm, rated torque >1 Nm, rated voltage 24V, rated speed 3000 rpm, 4 pole pairs, 3 phases.
  • Communication：Canbus communication (for precise fleet control and telemetry feedback).
 

Step 2: Initial Selection & Customization (First Prototyping)

  • Product Combination: Utilized JKIDS60-C01A integrated motor with a helical gear shaft.
  • Customization: Modified the output shaft (helical gear) to fit the customer's proprietary gearbox. Customized the pigtail cable length to 200mm with VH 3.96 4P connectors.
  • Testing Feedback: The customer reported a noticeable "backward drifting/overshoot" after the stop command was issued, impacting positioning accuracy. Diagnosed as a rigidity or acceleration setting issue; tuning internal parameters was recommended.
 

Step 3: Fault Diagnosis (Second Prototyping)

  • Design Pivot: Introduced a secondary option combining the JKIDS60-C01A with an RV30 worm gearbox (1:60 gear ratio) to significantly boost output torque.
  • Field Failure: During testing, the motor emitted a grinding noise, CAN communication dropped, and the red LED indicator flashed an error code.
 

Step 4: Root Cause Analysis (Failure Analysis)

  • Mechanical Interference: Poor quality of the customer’s gearbox caused excessive resistance or shaft misalignment.
  • Thermal Failure: Prolonged overload/stall caused severe overheating. Due to the Gen-1 motor lacking thermal protection, it eventually burned out.
  • Wiring Hazard: Frequent motion caused the original wiring to come loose.
 

Step 5: Final Optimization & Mass Production (Third Prototyping & Rollout)

Step 5.1: Hardware Upgrade (IDC60 Series Motor)

  • Safety Protection: Upgraded to Gen-2 integrated motors featuring built-in thermal protection to prevent burnouts under abnormal loads.
  • Ruggedized Interfaces: Standardized on high-reliability VH 3.96 connectors and streamlined the cable to 4 wires to enhance vibration resistance.
 

Step 5.2: Technical Specification Profiles: JKONGMOTOR IDC60 & IDC80 Series

JKONGMOTOR's heavy-duty industrial-grade IDC series intelligent integrated servo motors represent the gold standard for mobile automation chassis ranging from 200W up to 1000W output capacities.
Model Power (W) Rated Voltage (VDC) Rated Current (A) Rated Speed (rpm) Rated Torque (N.m) Body Length L (mm) Encoder communication protocol （choose）
JKIDC60-P124A1 200 24 11.5 3000 0.63 98.3 17bit RS485/CANopen/EtherCAT
JKIDC60-P148A1 200 48 6.5 3000 0.63 98.3 17bit RS485/CANopen/EtherCAT
JKIDC60-P248A1 400 48 11.5 3000 1.27 116.3 17bit RS485/CANopen/EtherCAT
JKIDC80-P148A1 750 48 20 3000 2.4 143.5 17bit RS485/CANopen/EtherCAT

Step 5.2: Dual-Configuration Options

  • Helical Shaft Version: To interface with the customer's existing drivetrain.
  • RV30 Gearbox Version: To deliver high torque and self-locking capabilities for heavy-duty conditions.
 

Step 6: Conclusion

Conclusion: Successfully eliminated the positioning drift, vastly improving the AGV's electrical and mechanical stability under demanding field conditions.
 

Solution Advantages

  • High load capacity: The servo system supports triple overload of the motor.
  • High positioning accuracy: The motor is equipped with a high-precision encoder and the drive uses an S-curve to plan acceleration and deceleration, the AGV starts and stops gently.
  • Save space: Compact design. Integrated servo motors reduce cables, and easy to wire.
  • Open communication with control system: CANopen (CiA 301  CiA402)
 
 
 

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Product Manuals

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Jkongmotor Integrated Dc Servo Motor User Manual.pdf

Integrated Servo Motor

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Jkongmotor Integrated Servo Motors RS485 Communication Protocol Manual.pdf

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Jkongmotor Integrated Servo Motors CANopen Communication Protocol Manual.pdf

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Jkongmotor IDC Series Integrated DC Servo Motor Catalog 2025.pdf

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Top 5 Benefits of Low-Voltage Integrated Servo Systems in AGVs & AMRs

1. Ultra-Compact Profile and Integrated Wheel-Drive Flexibility

Modern medical logistics robots and slim warehouse AGVs operate under severe physical space constraints. Advanced motion systems solve this by shrinking the frame layout.
  • The Integrated Benefit: By eliminating standard drive cabinet layouts, these motors can fit directly into the AGV's driving wheel hub.
  • IDC Series Optimization: JKONGMOTOR's IDC60 features a baseline body length of just 98.3 mm. This ultra-short profile allows AGV designers to save space for larger Li-ion battery packs, advanced LiDAR arrays, and onboard HMI screens without expanding the robot's physical turning radius.
 
 

2. Closed-Loop Negative Feedback for Expert Positioning Precision

AGVs are no longer constrained to straight, predictable paths. Modern industrial AMRs must carry heavy pallets across uneven warehouse thresholds, climb ramps, and execute complex spin-turns with millimeter-level target positioning accuracy.

  • Absolute Encoder Optimization: Traditional open-loop stepping systems or low-end motors suffer from step-loss, inertia overshooting, and forward/backward drifting during sudden stops. The IDC60 and IDC80 series resolve this by utilizing a 17-bit single-turn/multi-turn absolute encoder.
  • This high-resolution closed-loop feedback provides real-time telemetry to the 32-bit M4+ core. It ensures instantaneous velocity compensation over sloped terrain, eliminates the need for tedious homing routines upon reboot, and keeps the payload stable along complex axes.
 
 

3. Superior Thermal Efficiency and Heavy Load Capitalization

Heavy load AMRs deployed in automotive logistics or steel yards often haul payloads exceeding 1 to 5 tons. These applications require high current outputs without inducing destructive thermal spikes.

  • The Engineering Edge: Industry-leading servo architectures utilize efficient internal switching components to output high continuous currents smoothly.
  • IDC80 High Power Density: For high-load logistics platforms, the IDC80 750W-1000W system operates stably across 48V/72VDC architectures, delivering continuous rated torques up to 3.2 Nm. Built-in brake resistor interfaces and smart thermal sensor protection prevent motor burnouts caused by prolonged mechanical stalls or high wheel friction, maintaining optimal efficiency under demanding duty cycles.
 
 

4. Multi-Protocol Fieldbus Interconnectivity and Industry 4.0 IoT Readiness

Industrial automation networks require multi-axis synchronization and decentralized data acquisition capabilities.

  • Fieldbus Interconnectivity: Modern integrated servo drives allow plant operators to monitor diagnostic health, change operational profiles, and upload software solutions directly via an office computer or warehouse central PLC.
  • Communication Protocols: The IDC60 and IDC80 lineups offer extensive protocol support, featuring native compatibility with Pulse Train, RS485-Modbus-RTU, and CANopen network control architectures. This variety empowers system integrators to configure and tune multi-axis robot clusters remotely over existing warehouse networks, making predictive maintenance a reality.
 
 

5. Modular Plug-and-Play Design for Rapid Factory Deployment

Building standalone conveyor setups or designing discrete motor-drive frames can take months of complex programming and hardware debugging.

  • The Modular Solution: Integrated servo motors offer plug-and-play convenience. They connect easily to legacy controllers and microcontrollers, cutting down installation time and shortening commercialization lifecycles.
  • One-Stop Assemblies: JKONGMOTOR streamlines this by providing a comprehensive, customized modular ecosystem. Designers can select pre-configured options that combine an integrated servo motor with Precision Planetary Gearboxes, Right-angle Planetary Gearboxes, Worm Gearboxes, or 24V/48V Electromagnetic Holding Brakes. This eliminates messy field wiring and simplifies ongoing system maintenance.
 
 

Why Choose Jkongmotor?​​​​​​​

—— OEM ODM Customized Intelligent Integrated BLDC / Steper Motion Control Manufacturer / Solution Provider Since 2011 ——
  • OEM ODM Customized Service OEM ODM Customized Service
  • Motion Control Industry Solutions Provider Since 2011 Motion Control Industry Solutions Provider Since 2011
  • 7000 Square Meters Factory Areas 7000 Square Meters Factory Areas
  • Quality Stability Guaranteed By Precision Automatics Manufacturing Quality Stability Guaranteed By Precision Automatics Manufacturing

About JKONGMOTOR

    —— Your Motor Solution Experts: Delivering Expertise You Can Trust

CHANGZHOU JKONGMOTOR CO.,LTD. was founded in 2010,is a professional high-tech manufacturer of stepper motors and brushless motors.Now 100+ employees, workshop area of 7,000 square meters.
 

We are a professional manufacturer in Changzhou city, China. Production Capacity exceeds more than 2 million motors per year. Our Company offers many major series of products: Hybrid Stepper motors, Closed Loop Stepper Motor, Linear Stepper Motor, Brushless Dc motor, Dc Brush motor, Motor Driver, Geared Motor, Brake Motor, PM Stepper Motor, Power Supply and so on... We are always continues develop new type models.

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High-Precision Mechanical Shaft Modification

To reduce mechanical backlash and eliminate redundant, loose coupling linkages, the output shafts must often match specialized wheel profiles perfectly.
JKONGMOTOR offers precise customized machining services on motor shafts, including Hollow Shafts, Integrated Keyways, Pulleys, Helical Gears, Cross-Drilled Pins, and Flanged Ends, ensuring a rigid mechanical fit with the AGV's transmission setup.
  • ISO9001, ISO14001, CE, RoHS, Reach Certificated
  • Various New R&D Patents
  • More Parts: Gearbox, Encoder, Brake, Integrated Driver and so on...

Partner with a One-Stop Integrated Motion Control Solution Provider

Investing in high-performance integrated servo hardware optimizes long-term machine reliability and drives down the Total Cost of Ownership (TCO). Since 2011, Changzhou Jkongmotor Co., Ltd. has combined engineering design with factory-floor scalability, delivering thousands of robust, customized low-voltage BLDC servo components to manufacturers worldwide.
  • Stepper Motor & Bldc Motor with Integrated Drivers
  • Pulse & RS485 & CANopen & EtherCAT
  • Waterproof type: IP30 IP54 IP65 optional
  • Gearbox, Encoder, Brake, Lead Screw...
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Accelerate Your AGV Prototype to Mass Production Lifecycle

Whether you require a custom sample batch to prove a new AMR concept or are ramping up production lines to handle global distribution, choosing a partner with an established supply chain ensures your parts are delivered on time, within budget, and to your exact specifications. Contact our application engineering team today to request a custom motor prototype or layout your technical motion control consultation.
  • Strong R&D & Production Capacity
  • 24-H Online Service

Get Updated Article And News

—— OEM ODM Customized Intelligent Integrated BLDC / Steper Motion Control Manufacturer / Solution Provider Since 2011 ——

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Certificates Display Obtained by Jkongmotor

Our company has strong technical force, mature production technology, complete inspection equipment, excellent quality assurance system and service system, we have obtained ISO9001 quality management system certificate and ISO14001 environmental management system certificate, all the products have obtained CE, Reach certification, and comply with the EU RoHS requirements.
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Patents by Jkongmotor

As a professional motor manufacturer, JKONGMOTOR specializes in cutting-edge R&D and design. Supported by numerous industry patents, we provide expert, innovative solutions to ensure the success and reliability of every project.

Answers to Common Queries about Jkongmotor

—— OEM ODM Customized Intelligent Integrated BLDC / Steper Motion Control Manufacturer / Solution Provider Since 2011 ——
  • 1. What are the advantages of using a space-saving integrated dc servo motor in warehouse AGV drive systems?
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    A space-saving integrated dc servo motor blends the brushless motor, high-resolution encoder, and digital drive into a single housing. For warehouse AGVs (Automated Guided Vehicles), this highly integrated design eliminates external motor cabling, significantly reducing failure points. It maximizes internal chassis layout flexibility, leaving more room for high-capacity batteries and sensor arrays to improve runtime and structural safety.
  • 2. How does JKONGMOTOR provide oem odm customized integrated servo motors for compact AMRs?
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    As a leading high-tech enterprise with over 15 years of motion control experience, JKONGMOTOR delivers comprehensive oem odm customized engineering services. For compact AMRs (Autonomous Mobile Robots), we customize specialized output shafts (such as helical gear shafts or planetary gear reducers), modify pigtail cable lengths, alter terminal connector types (like heavy-duty VH 3.96 connectors), and adapt mechanical flanges to guarantee seamless mechanical drop-in replacement.
  • 3. Which communication protocols are supported by an integrated dc servo motor for SLAM-guided automated guided vehicles?
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    JKONGMOTOR's industrial-grade integrated dc servo motor lineups (such as the IDC60 and IDC80 series) natively support standard fieldbus communication protocols, including CANopen, Modbus-RTU, and EtherCAT. These protocols allow AGV central controllers to perform real-time multi-axis synchronization, query diagnostic codes, and receive telemetry data via a single bus line, simplifying wire routing.
  • 4. Can a factory-configured integrated dc servo motor with built-in thermal protection prevent AGV motor burnout?
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    Yes. JKONGMOTOR’s second-generation integrated dc servo motor systems feature embedded smart thermal sensors and protection logic. If an AGV encounters an unexpected mechanical jam, high wheel friction, or a prolonged stall condition, the onboard driver instantly detects the temperature spike and triggers a protective fault code, shutting down power before hardware failure or a coil burnout occurs.
  • 5. What options are available for an oem odm customized low-voltage integrated servo drive for heavy-load logistics robots?
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    JKONGMOTOR manufactures versatile low-voltage oem odm customized solutions operating from 24VDC, 36VDC, up to 48VDC/72VDC. For heavy-load logistics robots and lifters, we can integrate high-torque planetary gearboxes or RV30 worm gear reducers (such as a 1:60 ratio) alongside electromagnetic holding brakes to deliver strong holding torque and robust self-locking capacities during vertical lifting or ramp parking.
  • 6. How does an integrated dc servo motor with a 17-bit absolute encoder improve automated guided vehicle positioning accuracy?
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    Utilizing an integrated dc servo motor equipped with a high-resolution 17-bit absolute encoder gives automated guided vehicles pinpoint positioning resolution. The absolute feedback tracks precise wheel rotation and eliminates the need for homing routines upon power-up, solving common AGV navigation issues like inertia-induced sliding, backward drifting, or positioning overshoot during high-speed sorting.
  • 7. Does JKONGMOTOR offer waterproof IP65 oem odm customized integrated servo motors for outdoor agricultural AGVs?
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    Yes, our factory offers robust oem odm customized engineering for harsh environmental protection. We design and manufacture IP65-rated waterproof integrated brushless servo systems using special shaft seals, moisture-resistant enclosures, and industrial-grade waterproof connectors, protecting internal electronics against dust, rain, and chemical washes in outdoor or cold-chain logistics environments.
  • 8. Why is a NEMA 24 integrated dc servo motor ideal for automated e-commerce sorting shuttles?
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    A NEMA 24 (60x60mm) integrated dc servo motor strikes the perfect balance between high power density and a compact footprint. Delivering peak torques up to 2 Nm and rated speeds up to 3000 rpm, it provides the rapid dynamic acceleration, deceleration, and high-frequency start-stop cycles required by high-speed e-commerce sorting shuttles and micro-fulfillment robots.
  • 9. What quality control processes does your factory implement for wholesale oem odm customized brushless dc servo motors?
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    JKONGMOTOR operates under rigid ISO9001 and ISO14001 quality management systems. Every batch of wholesale oem odm customized motors undergoes strict incoming material inspection, dynamic rotor balancing, thermal imaging under load simulation, and comprehensive automated testing for CANbus communication integrity before shipment. All products carry CE, RoHS, and REACH certifications.
  • 10. How does a closed-loop integrated dc servo motor compare to traditional stepper motors in high-speed AGV steering systems?
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    Compared to open-loop or closed-loop stepper motors, a high-performance integrated dc servo motor provides a broader speed range, flat torque curves up to 3000 rpm, and superior load adaptability. In AGV steering units, its highly dynamic closed-loop response prevents steps from dropping under sudden load fluctuations, ensuring precise steering tracking angles and smoother obstacle avoidance maneuvers.

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