1. Overview
What it is: a low-speed electric cart-style robot with a flat deck and guarded frame that carries one tote bin or a small stack of bins between storage shelves, staging areas, and packing tables.
Who it is for: warehouse and back-of-house teams that need a simple way to reduce short walking trips, repetitive lifting, and small-bin handling.
How it will be used: an operator places a bin onto the deck, drives the robot slowly through indoor aisles, and drops the bin at a destination station. It is intended for smooth floors, clear aisles, and supervised use.
Main goals
- Move one 100 lb payload safely over short indoor distances.
- Keep the footprint narrow enough for warehouse aisles.
- Use common off-the-shelf parts where possible.
- Keep speed low enough for pedestrian environments.
All dimensions and ratings below are approximate and should be confirmed by a professional before any build or use.
2. Key specs
| Spec | Estimated value | Units | Notes |
|---|---|---|---|
| Overall length | 48 approx. | in | Includes front bumper and rear handle area. |
| Overall width | 28 approx. | in | Fits typical warehouse aisles more comfortably than a wider cart. |
| Overall height | 46 approx. | in | Measured to the top of the sensor mast. |
| Deck height | 12 approx. | in | Low loading surface for bins and totes. |
| Payload | 100 approx. | lb | Rated target load; confirm stability and braking margin. |
| Robot weight | 140 to 220 approx. | lb | Depends on frame, battery, and drive components. |
| Drive power | 500 to 900 approx. | W | Low-speed indoor electric drive. |
| Top speed | 2 to 3 approx. | mph | Walking pace for shared spaces. |
| Runtime per charge | 4 to 8 approx. | hours | Depends on duty cycle, floor condition, and battery size. |
| Materials | Steel tube, aluminum panel, rubber tires, poly deck, battery pack | — | Common, serviceable, indoor-friendly choices. |
| Turning style | Short-radius or differential drive | — | Exact layout to be chosen with stability and aisle width in mind. |
3. Drawings
4. 3D concept model
A simple volume model in the same units, meant to show approximate part placement only.
5. How it works
The robot uses a low-speed electric drive system to move along indoor floors. The battery supplies the motors and controls, and the operator steers it with a simple panel or handle interface.
The flat deck carries a tote or bin, while side guides help keep the load centered. A low deck height makes loading easier and reduces lift effort.
Sensors and simple safety logic would help slow or stop the robot if it encounters a person, obstacle, or unexpected condition. The exact sensing package depends on how crowded the warehouse is and what level of autonomy is desired.
This concept assumes supervised operation first, with possible future upgrades for route following or assisted navigation if the site needs it.
6. Parts and materials
| # | Part | Typical spec | Qty | Est. price / unit | Est. total | Supplier type |
|---|---|---|---|---|---|---|
| 1 | Battery pack | Approx. 24V to 48V rechargeable pack | 1 | US$500 to $1,500 | US$500 to $1,500 | Battery supplier or industrial distributor |
| 2 | Motor controller and basic electronics | Industrial controller, fuse protection, wiring, switches | 1 set | US$400 to $1,200 | US$400 to $1,200 | Automation or robotics supplier |
| 3 | Drive motors and gear reduction | Two-wheel drive or equivalent low-speed drive set | 2 | US$300 to $900 | US$600 to $1,800 | Mobility or equipment supplier |
| 4 | Main frame and deck | Welded steel tube, top panel, mounting plates | 1 | US$900 to $2,000 | US$900 to $2,000 | Fabrication shop or metal supplier |
| 5 | Wheels and casters | Industrial tires or wheels rated above load target | 4 | US$60 to $250 | US$240 to $1,000 | Industrial hardware supplier |
| 6 | Safety sensors | Bumper switch, obstacle sensing, status lights | 1 set | US$300 to $1,000 | US$300 to $1,000 | Automation supplier |
| 7 | Operator controls | Start, stop, emergency stop, direction control | 1 set | US$150 to $500 | US$150 to $500 | Industrial controls supplier |
| 8 | Battery charger | Matching charger for selected battery chemistry | 1 | US$150 to $500 | US$150 to $500 | Battery supplier |
| 9 | Fasteners, guards, covers | Bolts, corner guards, covers, cable clamps | 1 lot | US$200 to $700 | US$200 to $700 | Hardware and industrial supply |
Rough total budget range: about US$3,440 to US$10,200 before labor, engineering, testing, and contingency. A more realistic project total may still land near the stated budget once fabrication, controls integration, and safety work are included.
Prices are typical retail estimates only and can change by supplier, region, and specification.
7. Build phases
8. Safety, rules and permits to check
Rules depend on the country and state, and the exact requirements depend on whether the robot is treated as an internal material-handling cart, a powered industrial device, or a custom mobile machine.
- Electrical rules: battery, charging, wiring, disconnects, and emergency stop practices. Usually handled by local electrical code authorities and inspectors.
- Workplace safety: pedestrian interaction, speed limits, visibility, guarding, and operating procedures. Usually handled by workplace safety authorities and the employer’s safety program.
- Mechanical safety: load rating, stability, braking, pinch points, and guarding. Usually reviewed by an engineer and sometimes an insurer or equipment inspector.
- Fire safety: battery charging location, ventilation, and storage. Usually handled by fire code officials.
- Facility rules: aisle clearance, floor loading, and traffic routes. Usually handled by the building owner or facility manager.
- Insurance and liability: proof of design review, maintenance, and operator training. Usually handled by the owner’s insurer.
9. Who to involve
Mechanical engineer: checks frame strength, stability, wheel layout, and payload handling.
Electrical engineer or controls technician: checks battery sizing, wiring, controller selection, protection devices, and charging.
Fabricator or machinist: checks whether the frame and mounts can be built cleanly and repeatably.
Safety professional: checks operator procedures, aisle use, warning labels, and interaction with people.
Facility manager: checks aisle widths, floor conditions, charging placement, and workflow fit.
Insurer or compliance consultant: checks whether extra documentation or testing is needed before use.
10. Open questions to decide next
- Should it be fully manual, assisted, or partly autonomous?
- What exact bin size and load center will it carry most often?
- How narrow must it be to fit the real aisles and doorways?
- What floor surface and slope range must it handle?
- How long should a charge last in a normal shift?
- What safety sensing is needed for the actual warehouse traffic?
- Should the deck lift, tilt, or stay fixed?
- Which parts should be off-the-shelf and which should be custom fabricated?
Notes
This concept draft is intentionally approximate and meant to support planning conversations only. It is not a construction package, certification package, or final engineering design.