AGV / AMR Design and Development in India: Heavy Payload Mobile Robots, explained simply.
Off-the-shelf AGVs from MiR, Mobile Industrial Robots, and Geek+ are excellent — and expensive. For Indian warehousing and manufacturing budgets, custom AGV / AMR programs often pencil out better. Here's the playbook for building one that actually ships.
Core idea
What this blog covers
Indian warehousing and manufacturing budgets rarely justify the ₹40-80 lakh price tags of imported AGVs. Custom programs at 30-50% of that cost are achievable — but only with vendors who can integrate mechanical design, drive-train, embedded electronics, and ROS 2 software as one program. Most vendors specialize in one slice and farm out the rest, which adds risk and timeline.
Main discussion
Drive-train selection — skid-steer vs differential vs omni
Skid-steer (tank-style) is the simplest, most robust, and cheapest. Trade-off: scuffing on the floor when turning, slightly higher power draw. Fine for most Indian warehouse and factory floors. Differential drive (two driven wheels + casters) is smoother on the floor but has a turning constraint. Omni-wheel and mecanum are most agile but mechanically complex and expensive. We default to skid-steer unless the application specifically demands otherwise.
Mechanical chassis and payload structure
Steel weldments are common but heavy. Aluminium extrusion (80/20-style) is faster to iterate but less rigid. For 50-100 kg payload, aluminium frames with steel reinforcement at the drivetrain mount points hit the right balance. The chassis design also has to consider battery placement (low and central for stability), sensor mounting (LiDAR at consistent height, cameras with clear field-of-view), and access panels for maintenance.
Sensor stack — LiDAR is the production default
2D LiDAR (RPLidar A1 / S1, Slamtec) at ~₹15,000-40,000 for indoor SLAM. 3D LiDAR (Velodyne, Livox, Ouster) at ₹2-8 lakh for outdoor or complex 3D environments. RGBD camera (Intel RealSense, ZED 2i) for short-range obstacle detection and dynamic obstacle classification. IMU for dead-reckoning. Wheel encoders. For most Indian indoor warehousing, 2D LiDAR + IMU + wheel encoders is the cost-effective sweet spot.
ROS 2 software stack
Nav2 for navigation (costmap, planner, controller). slam_toolbox or RTAB-Map for mapping. nav2_lifecycle_manager for orchestration. Custom behavior tree for application-specific task logic. Foxglove or RViz for visualization and debugging. The software work is roughly 30-40% of the total project cost; the mechanical, electrical, and integration work is the bulk.
Commissioning and what to budget for
Plan 4-8 weeks of on-site commissioning at the client facility — this is where the robot meets reality. Floor materials, lighting, dynamic obstacles (forklifts, people, pallets), Wi-Fi reliability, integration with the warehouse management system. Skipping commissioning is the most common reason Indian AMR programs underperform. Budget for it in the contract, not as an extra.
Working with Yantrix on AGV / AMR programs
We've delivered 80 kg payload AMRs with skid-steer drive, Nav2 navigation, LiDAR SLAM, and full ROS 2 stacks. Programs include mechanical design, embedded electronics, ROS 2 software, simulation environment, and on-site commissioning. Send us your warehouse / factory layout and payload requirements and we'll come back with a phased quote within a business day.
Key takeaways
What readers should remember
- Skid-steer drive is simpler and cheaper than differential or omni-wheel for most warehousing applications.
- LiDAR SLAM is the production default for indoor navigation in Indian warehouses.
- Plan for 50-100 kg payload as the typical Indian use case — beyond 200 kg, drivetrain costs jump.
- Custom AMR program timelines: 5-9 months from kickoff to commissioning; rush programs are possible but expensive.
Have a machine to build? Let's scope it together.
Tell us about your project. We'll respond within 1-2 business days with a preliminary scope and timeline — no boilerplate, no up-sell.