Engineering the Future of Battery Logistics: Martin Záhradník on the Power of AGV U3200
Date: October 28, 2025, by Asseco CEIT
In this exclusive interview, AGV Technical Engineer Martin Záhradník from Asseco CEIT unveils how the AGV U3200 series is transforming battery manufacturing. Designed for loads up to 3,200 kg, the U3200 combines precision handling, intelligent safety systems, and 5G-ready connectivity to meet the industry’s highest standards.
Discover how innovation, engineering excellence, and sustainability come together to power the next generation of automated battery production.
In the rapidly evolving landscape of electric vehicle and battery production, manufacturers face increasing demands for precision, safety, and efficiency when handling extremely heavy materials. What specific qualities and technologies make the AGV U3200 series stand out as a unique solution for battery manufacturing environments?
The U3200 series is specifically designed for high-load operations up to 3,200 kg and offers unique features such as omnidirectional movement, full 360° safety coverage and wireless safety communication with assembly lines. These features are crucial in manufacturing environments where precision and safety are essential. Additionally, our AGVs allow customization to meet specific customer needs, which provides a significant competitive advantage.
When evaluating an AGV solution for demanding industrial applications such as battery production, which technical specifications of the U3200 series do you consider the most critical for ensuring optimal performance and adaptability?
Key specifications include a maximum load capacity of 3,200 kg, hydraulic lifting up to 500 mm, an advanced contour-based navigation system, a maximum speed of 1.5 m/s, and a minimum turning radius of 0.9 m. The modular design also allows customers to tailor the system to their operational requirements.
In modern production environments where humans and robots share the same workspace, safety is absolutely critical. How does the U3200 series ensure reliable and intelligent protection for both operators and equipment while maintaining smooth, uninterrupted operations?
Safety is our top priority. The U3200 series features multi-layered safety technology, including 2x 270° SICK scanners with optional integration of 2D scanners and 3D cameras. Dynamic safety zones adjust based on the vehicle’s speed, the type of material being transported, and its position in the production space. Our AGVs can operate in human environments without the need for isolation, offering a significant advantage over competitors.
What specific challenges arise when integrating AGVs into battery production lines, and how does the U3200 series overcome the demanding requirements for precision, synchronization, and seamless interaction with robotic workstations?
Battery production has unique requirements, such as millimeter-level precision when handling battery cells. Our AGVs address this with high precision contour-based navigation. Additionally, we offer hydraulic lifting up to 500 mm, enabling direct integration with robotic stations without additional centering devices.
Given the growing number of automated guided vehicle suppliers and the rapid technological advancements in industrial automation, how does the U3200 series distinguish itself from other AGV solutions on the market? What specific technological, operational, and safety innovations make your system truly stand out in demanding environments such as battery manufacturing or heavy-load intralogistics?
The U3200 series is designed with legislative compliance, customer-specific customization, and seamless integration with third-party systems through VDA 5050 standard support. We also provide 24/7 support, minimizing downtime and ensuring quick problem resolution. The most unique feature is safety positioning which we feel as must have feature to be combined with wireless safety communication with assembly lines.
We’re not just building machines – we’re engineering systems that bring intelligence, safety, and sustainability into production.
As industrial connectivity continues to evolve, 5G is often cited as a game-changer for smart manufacturing and automation. How do you see 5G technology shaping the future of AGV systems, and what specific advantages does it bring to solutions like your U3200 series and the Twiserion Fleet Manager platform?
5G technology offers high bandwidth and low latency, crucial for Industry 4.0 applications. Our Twiserion Fleet Manager platform is already 5G-compatible, enabling advanced real-time fleet coordination, predictive maintenance, and integration with existing ERP and manufacturing systems. This technology eliminates issues caused by WiFi roaming.
With industries worldwide accelerating their digital transformation efforts, what key developments and emerging trends do you currently observe in the automation market? How are these changes influencing the way manufacturers invest in and implement AGV systems and other autonomous technologies?
We observe growing demand for automated solutions due to labor shortages, the need for greater production flexibility, and an increased focus on workplace safety. Companies are increasingly adopting systems capable of 24/7 operation, including during weekends.
When investing in automation, choosing the right AGV partner can define the success of your entire operation. What are the most important and insightful questions manufacturers should ask before selecting an AGV solution—questions that help reveal not just the technology’s capabilities, but also the supplier’s commitment to safety, customization, and long-term reliability?
First and the most important must be the question of safety – if supplier fully meet safety regulation needs. This means used safety components and way is signal from those safety components evaluated. Customers should also inquire about customization options, the level of safety features, compatibility with existing systems, and post-deployment support. It’s also essential to understand the results achieved by other customers in similar production environments.
Developing a high-performance AGV like the U3200 undoubtedly came with complex technical hurdles. What was the most significant engineering challenge your team encountered during the development process, and how did you manage to overcome it to achieve the final result?
The biggest technical challenge in developing the U3200 series was enabling the AGV to lift loads of up to 3,000 kg to a height of 500 mm, all while maintaining exceptional stability within a highly compact frame. Achieving this required a complete rethinking of the mechanical structure, hydraulic system, and center-of-gravity control to ensure that even during full-load lifts, the vehicle remains balanced, precise, and safe.
Our engineering team focused heavily on optimizing the chassis design and reinforcing the hydraulic lifting system to handle such extreme loads without compromising maneuverability or safety. The combination of robust structural engineering and advanced control software allowed us to reach the desired lifting performance within the limited dimensions of the vehicle.
Other complex features, such as safety positioning and wireless safety communication, were also implemented—however, our development specialists had already successfully solved these challenges in other AGV models, so for the U3200 they could be integrated and refined rather than developed from scratch.
The outcome is a powerful yet compact AGV that can lift and transport heavy materials with unmatched precision and reliability—proving that even within tight design constraints, innovation and engineering excellence can deliver outstanding performance.
Sustainability has become one of the defining priorities for modern manufacturing, influencing everything from product design to factory logistics. In this context, how does the U3200 series reflect Asseco CEIT’s commitment to building a greener, more energy-efficient, and socially responsible production ecosystem?
From the very beginning, Asseco CEIT has aimed to design safe, durable, and long-lasting products that contribute to both economic and environmental sustainability. The U3200 series was engineered with this philosophy in mind—focusing not only on performance and safety, but also on reducing the long-term environmental footprint of industrial operations.
Its energy-efficient drive and lifting systems minimize power consumption during operation, while smart charging technology and optimized battery management extend the lifetime of the power units, reducing waste and energy costs. The vehicle’s robust construction ensures a significantly longer service life compared to conventional transport systems, lowering the need for frequent replacements or resource-intensive maintenance.
Moreover, by replacing traditional forklifts and manual handling, the U3200 helps companies decrease emissions, noise, and operational waste inside production facilities. It also supports safer and more ergonomic workplaces, which aligns with broader goals of social responsibility and worker well-being.
Customers who share this sustainability mindset quickly recognize that this design approach generates a long-term positive impact—not just operationally, but also environmentally. Every U3200 deployed represents a step toward a smarter, cleaner, and more sustainable future in industrial logistics, embodying Asseco CEIT’s vision of innovation that drives both efficiency and environmental responsibility.
The future lies in adaptive, self-learning AGVs that analyze their environment, predict changes, and make intelligent decisions in real time.
From your perspective Martin what excites you the most about working with AGV technology right now?
What excites me the most about working with AGV technology right now is the incredible pace of innovation and the real, tangible impact it has on modern manufacturing. We’re witnessing a shift from simple material-handling robots to intelligent, interconnected systems that can think, communicate, and make decisions in real time. It’s inspiring to see how these vehicles have evolved from basic transport units into key enablers of smart factories, capable of interacting seamlessly with machines, people, and digital platforms.
For me, it’s not just about building machines—it’s about engineering systems that bring intelligence, safety, and sustainability into production. Each new generation of AGVs offers better navigation accuracy, higher energy efficiency, and greater adaptability, which means we’re solving problems that used to seem impossible just a few years ago.
What’s also incredibly motivating is seeing how our technology directly transforms customer operations. When we walk through a plant where our AGVs are running 24/7, safely coordinating with people and robots, it’s a reminder that we’re not only improving productivity—we’re helping shape the future of industrial work itself.
The mix of technical challenge, creativity, and long-term purpose makes working with AGV technology truly exciting. It’s a field where every innovation matters, every improvement counts, and every project brings us one step closer to a fully autonomous, intelligent, and sustainable manufacturing world.
How do you ensure that your AGVs remain adaptable as customer needs and technologies evolve?
Ensuring that our AGVs remain adaptable in a constantly changing technological and industrial landscape is one of our top priorities. From the very beginning of the design process, we focus on modularity, scalability, and open architecture—three key pillars that allow our vehicles to evolve alongside customer needs.
Our AGVs are built on a flexible hardware and software platform that supports easy upgrades and integration with emerging technologies. Whether it’s adopting new navigation methods, integrating advanced sensors, or aligning with standards like VDA 5050 for mixed-fleet communication, we make sure each system can grow without requiring a full redesign.
On the software side, our Twiserion Fleet Manager provides continuous updates and compatibility improvements, enabling smooth interaction with MES, ERP, and other digital manufacturing systems. This ensures that as customers digitalize their operations, our AGVs stay seamlessly connected and relevant.
We also maintain close partnerships with clients throughout the entire lifecycle of their systems. Their feedback often inspires new functionalities and improvements that we can roll out across the platform.
In short, adaptability isn’t an afterthought—it’s built into the DNA of our AGV design philosophy. By combining forward-looking engineering with ongoing software development and customer collaboration, we ensure that our AGVs remain future-ready, cost-effective, and aligned with the evolving demands of smart manufacturing.
As automation continues to advance toward fully intelligent manufacturing, how do you envision AI and machine learning shaping the next generation of AGV systems, and what impact will these technologies have on their performance and integration in the factory of the future?
AI and machine learning are set to become the driving force behind the next evolution of AGV technology. Until now, most AGVs have operated on predefined routes and rules—but the future lies in adaptive, self-learning systems that can analyze their environment, predict changes, and make intelligent decisions in real time.
Through AI-driven perception and decision-making, AGVs will be able to recognize patterns, detect anomalies, and optimize their routes dynamically based on live production data. This means less downtime, faster response to disruptions, and more efficient energy and traffic management across entire fleets. Machine learning will also enable AGVs to continuously improve performance over time—learning from daily operations to refine their navigation accuracy, obstacle handling, and maintenance scheduling.
At Asseco CEIT, we are already preparing for this transition. Our Twiserion platform is designed with AI integration in mind, allowing for predictive maintenance, intelligent fleet coordination, and deeper connection with ERP and MES systems. In the near future, this will evolve into fully autonomous logistics ecosystems, where AGVs collaborate seamlessly with other robots, systems, and even humans.
Ultimately, AI will transform AGVs from being simply automated to being truly intelligent partners in production—capable of adapting, learning, and continuously optimizing manufacturing processes to deliver higher productivity, safety, and sustainability.