What Communication Protocols Are Used in AGV Batteries?

As Automated Guided Vehicles (AGVs) become essential in warehouses, factories, and logistics centers, their power systems are crucial. This is as crucial as their mechanical design and navigation systems. Today’s AGVs are no longer simple battery-powered carts. Data-driven machines connect and operate as part of highly automated ecosystems.

At the center of this evolution lies battery communication technology. Modern AGV batteries do far more than store and deliver energy. Through advanced communication protocols, they exchange real-time data with vehicle controllers, fleet management systems, and charging infrastructure.

Understanding the communication protocols in AGV batteries is important for AGV manufacturers, system integrators, and industrial users. Knowing these protocols and their importance is essential.

Why Communication Protocols Matter in AGV Battery Systems

In early AGV designs, batteries were largely isolated components. Operators relied on basic voltage indicators or scheduled maintenance to manage power. In contrast, modern AGV fleets may include dozens or even hundreds of vehicles operating simultaneously, often in 24/7 environments.

Battery communication protocols enable:

• Real-time monitoring of state of charge (SOC) and state of health (SOH)

• Intelligent energy management and optimized charging strategies

• Seamless integration with AGV controllers and fleet management software

• Predictive maintenance and reduced unplanned downtime

• Enhanced safety through active fault reporting

Without reliable communication between the battery and the AGV system, achieving high efficiency and system-level optimization becomes extremely difficult.

The Role of the Battery Management System (BMS)

All AGV battery communication is built around the Battery Management System. The BMS is the "brain" of the battery pack. It collects data from cells and sensors. Then, it processes this data and sends important information to outside systems.

Key data typically managed by the BMS includes:

• Battery voltage and current

• Cell-level voltage balance

• Temperature at multiple points

• SOC, SOH, and remaining runtime

• Alarm and fault status

The communication protocol explains how the AGV controller or higher systems package, send, and understand this data.

Common Communication Protocols Used in AGV Batteries

Different AGV applications and system architectures require different communication solutions. Below are the most commonly used protocols in industrial AGV battery systems.

CAN Bus (Controller Area Network)

CAN bus is the most widely used communication protocol in AGV batteries and industrial vehicles.

Why CAN Is So Popular in AGV Applications

CAN was originally developed for automotive systems and has proven extremely reliable in harsh environments. Its robustness and real-time performance make it ideal for AGVs operating in factories and warehouses.

Key advantages include:

• High reliability and noise resistance

• Real-time communication capability

• Widely supported by AGV controllers and industrial equipment

• Strong error detection and fault handling

Typical Use Cases in AGV Batteries

In AGV battery systems, CAN is commonly used to transmit:

• SOC and SOH data to the vehicle controller

• Charge and discharge limits

• Temperature and safety status

• Fault codes and warning messages

CAN allows the AGV to dynamically adjust speed, load handling, or charging behavior based on real-time battery data.

CANopen

CANopen is a higher-layer protocol built on standard CAN bus hardware.

Why CANopen Is Used in AGV Systems

CANopen adds standardized communication objects and device profiles, making system integration easier when multiple components from different suppliers are involved.

Benefits include:

• Standardized data structure

• Easier multi-device integration

• Compatibility with many industrial automation systems

AGV Battery Applications

AGV batteries using CANopen can integrate smoothly with standardized AGV controllers, PLCs, and industrial networks, especially in European automation environments.

RS485 Communication

RS485 is another widely used protocol in AGV battery systems, especially in simpler or cost-sensitive designs.

Key Characteristics of RS485

• Long communication distance

• Simple hardware implementation

• Stable differential signaling

• Lower data rates compared to CAN

Typical Use Cases

RS485 is often used for:

• Basic SOC reporting

• Communication with charging stations

• Data logging and diagnostics

While RS485 lacks some advanced real-time features of CAN, it remains a reliable choice for many industrial AGV projects.

Modbus (RTU and TCP)

Modbus is a widely adopted industrial communication protocol, often layered on RS485 (Modbus RTU) or Ethernet (Modbus TCP).

Why Modbus Is Used in AGV Battery Systems

• Simple and well-documented protocol

• Easy integration with PLCs and industrial control systems

• Broad industry acceptance

Applications in AGV Projects

Modbus is commonly used when AGV batteries need to interface with:

• Warehouse management systems

• Factory automation systems

• Central monitoring platforms

It is particularly useful in facilities already standardized on Modbus-based infrastructure.

UART and Custom Serial Protocols

In some AGV designs, especially proprietary platforms, manufacturers use UART-based or custom serial protocols.

Advantages

• Highly flexible and customizable

• Optimized for specific AGV designs

• Low implementation cost

Limitations

• Limited interoperability

• Requires detailed documentation

• Less suitable for multi-vendor systems

These protocols are usually used in closed systems. In these systems, the AGV maker controls both the vehicle and the battery design.

Ethernet-Based Communication

As AGVs become more intelligent and connected, Ethernet-based communication is gaining attention.

Benefits

• High data bandwidth

• Easy integration with IT systems

• Support for advanced diagnostics and analytics

Current Limitations

• Higher cost

• More complex implementation

• Less common at the battery pack level

People commonly use Ethernet between AGVs and central systems. In the future, battery systems may use it more for advanced applications.

Wireless Communication and Future Trends

While wired protocols remain dominant for safety-critical battery communication, wireless technologies are emerging for monitoring and fleet-level analytics.

Examples include:

• Wi-Fi or industrial wireless for data aggregation

• Bluetooth for local diagnostics and maintenance

• Cloud connectivity for fleet optimization

These technologies typically complement, rather than replace, wired battery communication protocols.

How Communication Protocols Improve AGV Safety

Battery communication protocols play a critical role in AGV safety by enabling:

• Immediate fault reporting

• Automatic shutdown in abnormal conditions

• Controlled charging and discharging

• Thermal management coordination

By sharing accurate, real-time data, the battery and AGV controller work together to prevent unsafe operating conditions.

Choosing the Right Communication Protocol for AGV Batteries

Selecting the appropriate protocol depends on several factors:

• AGV controller compatibility

• Required data complexity and update frequency

• Operating environment

• System scalability

• Cost considerations

For most modern AGV projects, CAN or CANopen offers the best balance of reliability, performance, and industry support.

The Role of OEM Battery Suppliers

Professional OEM industrial battery suppliers play a key role in protocol selection and implementation. They work closely with AGV manufacturers to:

• Match communication protocols with vehicle control systems

• Customize data frames and message content

• Support testing and validation

• Ensure long-term reliability and compatibility

This collaboration is essential for successful AGV deployment.

The Future of AGV Battery Communication

As AGVs evolve toward greater autonomy and intelligence, battery communication will continue to advance. Future trends include:

• More standardized data models

• Deeper integration with fleet management systems

• AI-driven predictive maintenance

• Enhanced cybersecurity measures

Batteries will increasingly function as intelligent nodes within automated logistics networks.

Frequently Asked Questions (FAQ)

1. What is the most common communication protocol used in AGV batteries?

CAN bus is the most commonly used protocol because of its reliability, real-time performance, and wide industrial acceptance.

2. Why do AGV batteries need communication protocols?

Communication protocols allow the battery to share real-time data with the AGV controller, enabling safe operation, optimized energy use, and predictive maintenance.

3. What is the difference between CAN and CANopen?

CANopen is a standardized higher-layer protocol built on CAN hardware. It provides structured data formats and easier multi-device integration.

4. Are RS485 and Modbus still used in modern AGVs?

Yes. Many people still widely use RS485 and Modbus, especially in cost-sensitive or PLC-based AGV systems.

5. Can AGV batteries communicate with charging stations?

Yes. Many AGV batteries use communication protocols to exchange data with chargers, enabling controlled charging, fast charging, and opportunity charging.

6. Is wireless communication safe for AGV batteries?

People often use wireless communication for monitoring and diagnostics. In contrast, safety-critical functions depend on wired protocols like CAN.

7. Can communication protocols be customized for specific AGV projects?

Yes. OEM battery suppliers can customize communication protocols, data frames, and message content to match specific AGV requirements.

8. How does battery communication help reduce downtime?

By providing real-time health data and fault alerts, communication-enabled batteries support predictive maintenance and reduce unexpected failures.

9. Do communication protocols affect AGV scalability?

Yes. Standard protocols like CAN and CANopen help to grow AGV fleets. They also make it easier to add new vehicles or batteries.

10. What trends will shape AGV battery communication in the future?

Greater standardization, smarter data analytics, deeper system integration, and enhanced cybersecurity will define the next generation of AGV battery communication.