Intralogistic automation with BITO LEO
The LEO driverless transport system from BITO automates the in-house material flows reliably and economically – without requiring complex IT integration. The track guided navigation using optical lines means that the automated guided vehicle (AGV) can operate precisely, safely and with little maintenance effort. Fixed routes ensure transparent processes, low operating costs and a seamless connection between warehouse, production and mailing departments.
- Straightforward, scalable, modular and economical
- Optical, track guided navigation
- No IT integration necessary, though possible
- Perfect for confined spaces
What is the BITO LEO system?
The LEO system offers an alternative to freely navigating automatic guided vehicles (AGVs) which is easy to implement and track guided. While freely navigating AGVs come with high investment and integration costs, LEO works with optical track guidance technology: a coloured strip on the floor and printed markers with QR codes perform navigation – precisely, reliably and without complicated IT integration.
This means that material flows can be automated within a few days without requiring any intervention in existing IT or conveyor systems. The LEO transport robots automatically identify loading stations, transfer stations and destination points and travel along defined routes with precision. Routes can be adapted without external tools – the system grows with the processes, not the other way round.
As a result, companies receive a driverless transport solution with significantly lower investment and operating costs, and one that runs reliably when other systems long since required support. The BITO LEO system is robust, standardised and CE certified.
Practical examples and success stories using the BITO LEO system
Overview: four versions for different requirements
BITO’s LEO transporters are track guided driverless transport systems for the automation of in-house transport. Depending on the application, there are four versions available – from standardised container transport to customised special solutions.
LEO Locative – entry level automation
- For containers, trays, cartons
- Up to 35 kg
- Automates container and cardboard box transport processes between fixed workstations or with manual transfer
- For regular material flows in order picking, Kanban processes or interlinked machinery
LEO Carrier – the smart order picking assistant
- For containers, trays, cartons
- Up to 60 kg
- Collection vehicle can be used for order picking or as a “mobile buffer storage space”
- Tablet-based operation for versatile destination selection and order management
- Perfect for zone-based order picking and resupply processes
LEO Flow – driverless transport meets conveyor technology
- For all solid load carriers
- Up to 50 kg
- Equipped with a belt conveyor
- Can deliver goods directly to conveyor systems or collect them from there
- Supplements existing conveyor systems or automatically operated workstations
- Two versions: with a fixed height or scissor lift mechanism for height differences of up to 1600 mm
Control and navigation – optical guidance
The LEO system is controlled on the basis of optical track guidance. A coloured strip on the floor (blue or green) defines the route, while markers with QR codes send driving commands, stopping points, speeds or operations such as opening gates. This technology does not require full Wi-Fi coverage and allows fast adaptation of routes without programming.
The route guidance is precise and ensure repeat accuracy, as the vehicles are navigated along the track exactly. Markers can be repositioned or added as required to implement route changes, new destinations or traffic rules. If the routes change, an employee can reposition or remove the track strip – quickly, easily and without software adaptations.
Two versions of the LEO track strip are available for applications: the Flex track strip is particularly suitable for straightforward applications without high requirements of durability. The Robust track strip provides a more robust alternative and is resilient to floor cleaning activities.
Control using a tablet on the vehicle
- Direct control using a built-in tablet with the BITO app
- App: destination input, route programming, loading commands directly at the vehicle
- Standard feature for LEO Carrier, can be retrofitted as an option for LEO Locative, Flow and Custom
Control using a tablet and LEO Smart Box
- Destination input: separate vehicle and tablet (connected to Smart Box)
- Smart Box automatically communicates with the next available vehicle for an order
- Particularly suitable for LEO Flow and Locative
Control using bar codes
- Each load carrier is given a bar code with an assigned destination
- LEO bar code reader stationary or as a hand-held scanner
- After scanning, the next available vehicle receives the destination command by means of the LEO Smart Box
Control using customer bar codes
- Customer bar codes saved in the LEO Smart Box as CSV files
- Can be adapted at any time by the customer after a briefing
Control using warehouse management system
- LEO Smart Box features an automation interface
- RS232/RS485 interface for sending commands using external systems (e.g. warehouse management system)
- Central control of destination allocation for LEO
- Feedback about serial number, last destination, load and battery status upon return to the source station
Control using Com-Server and order control
- As an upgrade for complex processes: each Smart Box is equipped with a Com-Server to ensure network compatibility
- This means that a higher level control system can manage and control pick up and drop off points, loading stations or traffic regulation points in one system
- Availability of a suitable order management system from BITO
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The LEO models – the right system for every application
LEO Locative
The LEO Locative is the most straightforward and, at the same time, most efficient solution for automation of in-house container and cardboard box transport. The system works using standardised transfer stations at which the load is automatically picked up or dropped off as it passes through – without stopping.
Advantages:
- Automated transport of containers, cardboard boxes and trays between defined workstations
- Particularly suitable for order picking, machinery supply and Kanban processes
- Automatic pick up and drop off using standardised transfer stations or manual transfer by employees
- Drive through principle: containers are picked up/dropped off as they pass through the station without stopping for short cycle times
- Easy to upgrade: additional stations can be added at any time without system adaptation
- Ideal for unvarying material flows (e.g. between machines, shelf units or buffer zones)
Typical applications: incoming goods – storage, order picking – consolidation, interlinked machinery
LEO Carrier
The LEO Carrier is a track guided driverless transport system with an integrated shelf system for order picking and resupply processes. Different containers or goods can be transported simultaneously on several shelves. The system is controlled using a tablet directly on the vehicle, which can be used to select different destinations. This allows the carrier to support zone-based order picking and material resupply between storage and production areas while also reducing walking distances
Advantages:
- Provides support for employees with order picking, resupply and production orders with four storage or removal shelves
- All-in-one: can also be used as a manual order picking trolley or mobile buffer store
- 4 shelves each 655 × 495 mm, total effective load 60 kg
- Can transport several orders at the same time
- Versatile destination control using integrated tablet: order and route selection directly on the vehicle
- Enables zone-based order picking, in which several orders are processed simultaneously
- Home base function: returns to the starting position at the end of the order – saves search and waiting times
- Ideal for dynamic order picking and resupply processes, seasonal fluctuations or multi-shift operation
Typical applications: order picking, mailing preparation, production supply, multi-shift operation, resupply, returns processing
LEO Flow
The LEO Flow is a track guided driverless transport system with an integrated belt conveyor, which delivers loads directly to conveyor systems or picks them up from there. It therefore serves as a mobile connection between already installed conveyor systems, automated small parts warehouses and manually operated workstations. This adaptability allows the LEO Flow to be seamlessly integrated into existing systems and to support interlinking of different conveyor technology sections without having to install new stationary conveyor lines.
LEO Flow is available in two versions:
- Fixed height: for unchanging transfer heights, for example when connecting conveyor lines at the same level
- Scissor lift mechanism: with automatic height adjustment of the container holder for height differences of up to 1600 mm
Advantages:
- Interconnects automated conveyor technology – for use as a material flow bridge between automated systems without an additional conveyor section
- Automatic pick up and drop off of containers by means of an integrated belt conveyor
- Versions for fixed transfer heights or with an automatic scissor lift function
- Compatible with standard conveyor systems, automated small parts systems and buffer shelf units
- Seamless integration into existing material flow concepts
- Supports continuous operation at automatically operated workstations
Typical applications: connection of automatic storage systems, buffer and mailing areas, machine and line production
FAQ – frequently asked questions about the BITO LEO driverless transport systems
How does the LEO system work without Wi-Fi or a central control system?
The LEO transporters operate using optical track guidance: a strip on the floor defines the route, while markers with QR codes send instructions such as stops, turns or speeds. This means that the vehicles do not require any Wi-Fi, radio connection or software installation. New routes or changes are easy to implement by sticking on new markers – without requiring programming or external technicians. This makes the system particularly robust, cost efficient and quick to customise
What distinguishes the LEO system from other driverless transport systems?
In contrast to many conventional driverless transport systems, the LEO system does not require any complex IT integration or 3D navigation. Track guidance using markers is simpler, safer and requires less maintenance. Investment costs are also significantly lower, as there is no need for servers, Wi-Fi coverage or expensive commissioning by external service providers. LEO systems are ready for use in just a few days and are scalable, as new vehicles can be added at any time.
What versions of the LEO system are available and what are they suitable for?
The LEO product range is comprised of four different versions:
- LEO Locative: automated container transport between fixed stations
- LEO Carrier: mobile shelf unit system for order picking and resupply
- LEO Flow: for the connection of driverless transport systems and conveyor technology – with optional scissor lift mechanism up to 1,600 mm
- LEO Custom: customisable platform for special transport requirements and tugger trains. All systems can be combined and offer a standardised control logic and power supply.
How is the LEO system controlled and integrated into operations?
There are different options for the control system:
Using a tablet directly on the vehicle,
or by using a tablet with a Smart Box, which automatically assigns orders to the vehicles available. Neither version requires centralised software or Wi-Fi. Integration into an existing environment is straightforward: routes are marked, stations are positioned, markers are programmed – and it’s done. The entire process from set-up to operational start usually only takes a few days.
How long does the battery of a LEO transporter last for, and how is it charged?
The vehicles are equipped with LiFePo₄ batteries that provide up to 16 hours of operating time per charge.
Charging is done either manually by using the integrated charging connection or automatically with a contact charging station, which the LEO automatically drives to.
The batteries are low maintenance, hardwearing and particularly safe from overheating or deep discharge. With over 1000 charging cycles and low energy consumption (approx. 200 kWh/year), operation is extremely economical.
How safe is the operation of LEO transporters?
All LEO systems comply with the Machinery Directive 2006/42/EC and the ISO 3691-4 standard for driverless transport systems.
Due to track guided navigation, there is no risk of collision due to unexpected motions.
Sensors and safety bars automatically stop the vehicle in the event of encountering obstacles. As there is no Wi-Fi communication or cloud connection, the systems are also cyber-secure and operated entirely locally.
How fast the system to introduce?
A major advantage of the LEO transporters is the short introduction time:
Most projects can be implemented within two to five days – including installation of the track guidance system, transfer stations and test drives.
As no software installation or network connection is required, productivity is maintained during implementation. LEO is therefore also ideal for companies that wish to automate step by step.
What maintenance does the system require?
LEO systems are virtually maintenance free.
The vehicles only require regular visual inspections and a battery replacement after several years of operation.
As there is no complex sensor technology, no Wi-Fi communication nor central software, the typical maintenance costs of classic driverless transport systems are eliminated.
This significantly reduces operating costs and ensures maximum availability and a plannable cost structure.