AGV / AMR Troubleshooting
The most common agv / amr problems on the plant floor, with the likely causes and the fix for each. Part of the OEE Lab directory of 301+ documented problems.
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Problems on this page:
Battery or charging faults
Hits OEE: AvailabilitySymptoms: Short run time, fails to dock/charge, unexpected shutdowns.
Prevention: Battery health monitoring, charger/contact upkeep, dock alignment.
Safety stops or obstacle faults
Hits OEE: AvailabilitySymptoms: Frequent safety stops, robot freezes on phantom obstacles.
Prevention: Scanner cleaning/alignment, traffic management, field config.
AGV / AMR troubleshooting FAQ
AGV / AMR: what causes navigation or localisation errors, and how do I fix it?
Symptoms: Robot gets lost, deviates from path, misses drop points. Likely causes: Map or environment change; Dirty sensors or markers; Localisation tuning. Fixes: Re-map after layout changes; keep reference features stable. Clean LiDAR/cameras; restore floor markers/reflectors. Recalibrate localisation; check wheel-odometry/encoders. Prevention: Map management, sensor cleaning, localisation calibration.
AGV / AMR: what causes battery or charging faults, and how do I fix it?
Symptoms: Short run time, fails to dock/charge, unexpected shutdowns. Likely causes: Ageing battery or cells; Charger or contact fault; Docking misalignment. Fixes: Test capacity; replace degraded batteries. Clean charge contacts; service the charger/dock. Align the dock; check approach navigation. Prevention: Battery health monitoring, charger/contact upkeep, dock alignment.
AGV / AMR: what causes safety stops or obstacle faults, and how do I fix it?
Symptoms: Frequent safety stops, robot freezes on phantom obstacles. Likely causes: Dirty or misaligned safety scanner; Clutter or people in the path; Scanner field configuration. Fixes: Clean and align the safety LiDAR; check fields. Manage traffic lanes; keep paths clear. Review protective-field setup for speed/zones. Prevention: Scanner cleaning/alignment, traffic management, field config.
Stop the same fault coming back
Recurring agv / amr stops usually trace to a cause you cannot see by hand. The partner we recommend is Fabrico: EU-built, so your production data stays in EU jurisdiction, with computer-vision true-cause of micro-stops, a closed loop from PLC-read OEE to an auto-routed work order, and ISO 27001 / 20000-1 / 9001 (supports audit-readiness).
See how Fabrico finds root causeRelated tools: full troubleshooting directory · OEE calculator · downtime cost · MTBF / MTTR · glossary
Methods that cut recurring stops: the six big losses · root cause analysis · preventive vs predictive maintenance · TPM · SMED & changeover