RESOURCE CENTER > CASE STUDIES

AGV-Ready Guide Rail Hydraulic Lift｜2-Ton, 400mm Shallow Pit

POSTED: 6/12/2026

Overview

Project type: Guide rail hydraulic lift (2:1 speed)
Client: An intelligent logistics / smart manufacturing company (AGV application)
Industry: Smart factories, automated warehousing, flexible production lines
Key features: AGV direct docking, reserved AGV interface, shallow pit with 2:1 speed, floor interlock

Application Scenarios

The client is an enterprise focused on smart factory and automated logistics. Their workshop/warehouse already uses AGVs for material handling. However, AGVs only work on a single floor – they cannot move between floors.

Traditional practice requires manual unloading from AGVs and then using a forklift or freight lift to transfer goods to another floor.

This reduces efficiency, increases labour cost, and breaks the automated logistics chain.

Challenges

Shallow pit vs. high travel: Only 400mm pit depth but 3.5m travel required. A 1:1 cylinder cannot fit – a speed multiplier is needed.
Precise AGV docking: The AGV must automatically drive onto the lift platform. High levelling accuracy and reliable detection are required, plus signal exchange with the AGV control system.
Floor safety interlock: Two high‑speed rigid roller doors (one per floor) must be electrically interlocked with the lift – door not closed → lift cannot move; lift not at floor → door cannot open.
Heavy load & rigidity: 2‑ton capacity with a relatively large platform (1800×2000mm) – smooth lifting without wobble is essential.

Core Specifications

Parameter	Value
Model	SJD2.0‑3.0 (2:1 speed)
Rated load	2,000 kg
Travel height	3,500 mm
Platform size (W×D)	1,800×2,000 mm
Car internal height	2,200 mm
Pit depth	400 mm
Structure	2 cylinders, 4 guide rails, 2:1 speed
Guide rails	125H national standard ×4
Cylinders	Φ70‑50 ×2
Power unit	3 kW
Chains	1244 plate chain ×4
Wire ropes	#12 diagonal double levelling
Platform frame	120×60×4mm
Platform deck	4mm chequer plate
Lifting frame	100×50×4mm
Scissor base frame	160×80×4mm
Floor doors	High‑speed rigid roller doors ×2 (W2000×H2200), grey, interlocked
Safety device	Mechanical anti‑fall landing catch
Control	PLC, reserved AGV interface
Installation	Floor opening, 400mm pit
Colour	Grey
Special features	AGV drives onto platform, AGV interface ready

Solutions

2:1 Speed hydraulics – 3.5m travel from a 400mm shallow pit

Pit depth: 400mm (conventional 2‑ton lifts need 600‑800mm).
Solution: 2:1 speed mechanism (chain + pulley multiplier). Cylinders Φ70‑50 ×2 units. Cylinder stroke approx. 1.75m, multiplied 2× to achieve 3.5m car travel. Cylinders are installed vertically in the 400mm shallow pit – no deep excavation.
Guide rails: 125H national standard ×4 – ensure vertical accuracy.

AGV docking & interface reservation

Docking method: AGV drives directly onto the lift platform (platform size 1800×2000mm, height matched to AGV load deck).
Levelling accuracy: PLC control + limit switches guarantee levelling accuracy ≤±5mm – meets AGV automatic entry/exit requirements.
Interface reservation: Control system reserves an AGV interface (communication protocols such as Profinet, Modbus TCP, or I/O dry contacts). Later it can connect to the AGV dispatch system for automatic calling and position feedback.

Floor safety interlock & roller door coordination

Floor doors: Two high‑speed rigid roller doors (W2000×H2200mm), grey.
Interlock logic:
- If a roller door is not fully closed, the lift cannot start.
- If the lift is not precisely at a floor, the corresponding door cannot open.
- While the lift is moving, all doors remain closed.
Anti‑fall landing device: Mechanical catch – automatically locks the platform at each floor, preventing sinking if hydraulic pressure is lost.

Structure & materials

Car: W1800×D2000×H2200mm, fully enclosed with carbon steel chequer plate (three sides + top) – anti‑slip, wear‑resistant.
Platform frame: 120×60×4mm rectangular tube; deck 4mm chequer plate.
Lifting frame: 100×50×4mm rectangular tube; scissor base frame: 160×80×4mm rectangular tube.
Chains: 1244 plate chain ×4; wire ropes: #12 diagonal double levelling.
Power unit: 3kW, 380V/50Hz; hoses Φ18mm.
Colour: Grey.

Control & intelligence

PLC control: Automatic levelling, fault alarm, interlock logic.
Operation: Local push‑buttons/touch screen, or remote via the reserved interface.
Expandability: Reserved AGV interface – future upgrade to fully automated cross‑floor logistics.

Product Certificates

FAQ

Answer: A standard 1:1 cylinder would need at least 1.8m pit depth. Our 2:1 speed mechanism (chain + pulley multiplier) halves the cylinder stroke. Cylinder stroke 1.75m → multiplies to 3.5m lift. The cylinder fits into the 400mm pit. Safe, proven, and reduces pit depth by >70%.

Answer: No. The lift has a reserved communication interface (Profinet, Modbus TCP or I/O). The AGV sends a request → door opens → AGV drives onto platform → lift moves automatically → door opens at target floor → AGV exits. Fully automatic, no human button‑pushing.

Answer: Hard interlock logic:

Door not fully closed → lift cannot move.
Lift not exactly at floor → door cannot open.
While lift is moving → all doors stay closed.

Plus a mechanical anti‑fall catch (like a lift safety hook) – platform locks at each landing even if hydraulic pressure fails.

Answer: Yes. The reserved interface uses standard industrial protocols (Profinet / Modbus TCP / dry contacts) – not tied to any AGV brand. The control cabinet has spare I/O and Ethernet ports. The PLC already includes AGV‑call and position‑feedback function blocks. Only minor parameter changes are needed for new AGV communication. No hardware rework. Proven with clients who upgraded AGVs twice without on‑site modification.

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