Using EtherCAT technology to launch online automated guided vehicle manipulation with unity‐based platform for smart warehouse management

Abstract In Industry 4.0, the innovative concept of a smart warehouse is defined as a progressive development in logistics and operations management. Numerous advanced techniques are recommended for integration, including wearable devices, communication, loading/unloading, optimization, robotics, and automated transportation, among others. Currently, the growing demand for swift cargo distribution, cost‐effective labour utilization, and enhanced productivity stands as an urgent topic for both enterprises and scholars. This paper presents an EtherCAT‐based model of automated guided vehicle (AGV)‐manipulation introduced within the Unity platform for smart warehouse management. The working environment selected for this model is a cross‐docking warehouse with a chessboard layout. Initially, theoretical computations pertaining to mechanical design are established to provide accurate parameters. Subsequently, the structure of the TwinCAT Human–Machine Interface Server and the configuration within the Unity environment are outlined. Following that, the software architecture, encompassing data exchange and a set of motion commands, is meticulously explained. To validate the proposed approach, several laboratory tests are conducted under identical conditions. This research offers several contributions: firstly, it introduces the innovative use of real‐time technology to represent AGV systems; secondly, it elucidates the potential connection between virtual reality and the physical model; and thirdly, it employs fluid motion techniques to illustrate and visualize driving performance. These findings hold significant promise not only for the advancement of smart warehouse management but also for the broader landscape of digital trade.