ALFATEC developed a compact lift mast for a manufacturer of automated guided vehicle (AGV) solutions. The mast integrates into the vehicle in both form and function. It handles loads of up to 1,500 kg and provides a 1,700 mm stroke, while its slim design keeps the fields of view for cameras and scanners clear. Achieving high rigidity with a low dead weight was a key design requirement.

When the lift mast becomes part of the vehicle

In an automated guided vehicle, the lift mast is more than a functional component. It is part of a complete product that travels autonomously, picks up loads and moves safely through its surroundings. The solution therefore had to meet the technical requirements and fit the vehicle’s design.

The mast was designed to follow the contours of the AGV instead of appearing to be an add-on. At the same time, it had to meet every mechanical requirement: load handling, lifting movement, guidance and the interface with the vehicle.

A slim design that keeps sensors unobstructed

An AGV uses cameras, scanners and other sensors to navigate. These components need clear fields of view to detect their surroundings reliably. This created a central design challenge: the lift mast had to be rigid enough to handle the forces involved without obstructing the sensors or taking up unnecessary space.

ALFATEC therefore designed the mast to be particularly slim. Space and interfaces for sensors and attachments were considered as part of the overall system. The result is a lifting solution designed around the vehicle’s autonomous operation.

High rigidity with a 1,500 kg load capacity

A compact design still has to provide the required rigidity. ALFATEC combined precisely sized guide profiles and Tiger bearings with targeted reinforcements in highly loaded areas. Finite element analyses (FEA) showed how the mast would behave under load and where additional reinforcement was needed.

From prototype to series production

The solution was developed in close collaboration with the customer. Instead of adapting a finished mast to the vehicle, the team developed the product together, step by step. A prototype made it possible to test and refine its function, appearance, clearance for sensors and other details.

This development process produced a lift mast ready for series production and now used in larger quantities. The project demonstrates how a custom design can be transferred into a repeatable, stable production process.

The result: integrated, compact and ready for series production

The result is a lift mast designed as part of the AGV from the outset, rather than a standard product adapted afterwards. Load capacity, rigidity, available space, sensor placement and vehicle design were considered together. The solution can now be produced consistently in larger quantities.