“In many projects, planning for mobile robotics begins with the obvious question: How many vehicles are needed to achieve a specific transport capacity? This question is important, but it doesn’t go far enough. In later operation, the interaction of various influencing factors is what matters,” says Ralf Dohndorf, Vice President of Factory Simulation at DUALIS.
The behavior of the overall system is decisive
Traditional planning methods, such as using Excel, are no longer sufficient for today’s requirements. Often, multiple vehicles, varying order priorities, limited buffer areas, charging infrastructure, and other automation components interact. Even minor changes in the layout or order structure can have a noticeable impact on throughput, wait times, and utilization.
Companies today therefore face the question of how to realistically assess the behavior of a mobile robot system before making investments or finalizing layouts.
DUALIS provides a comprehensive solution for this with the 3D simulation platform Visual Components and the DUALIS Mobile Robots Library. Mobile robots are not viewed in isolation, but as an integral part of a holistic production or intralogistics system.
Simulation Becomes a Decision-Making Tool
With the DUALIS Mobile Robots Library, DUALIS extends Visual Components with functions for realistic planning and analysis of AGV and AMR systems. Companies can map vehicle movements, traffic rules, loading processes, and material flows in a shared 3D environment and compare different scenarios.
“Our simulation solution is not just for visualization; it is a tool for making informed decisions. Companies can assess even before implementation how many vehicles are actually needed, where bottlenecks occur, and how robust a system performs during peak loads or future scaling. They know how the system behaves under realistic conditions,” explains Ralf Dohndorf.
Holistic Approach Instead of Isolated Fleet Analysis
“Specialized tools for planning mobile robots exist on the market. These are generally well-suited for clearly defined transport processes or the isolated analysis of a vehicle fleet. A more comprehensive evaluation of the entire system is only possible to a limited extent with these tools,” says Dohndorf.
Visual Components, in combination with the DUALIS Mobile Robots library, on the other hand, enables an integrated 3D factory simulation in which mobile robots can be modeled together with other automation components.
The simulation supports companies throughout the entire project lifecycle—from the concept phase through planning and commissioning to optimization during ongoing operations. Simulation results provide measurable metrics on throughput, utilization, wait times, or energy consumption and create a solid foundation for investment and optimization decisions.
About DUALIS GmbH IT Solution
Founded in 1990, DUALIS GmbH IT Solution —a subsidiary of iTAC Software AG and part of the Dürr Group—specializes in the development of software and services related to simulation, process optimization, and production planning. The product portfolio includes the APS system GANTTPLAN, the 3D simulation platform Visual Components, and the plant layout tool AREAPLAN. DUALIS products are used by numerous companies in large-scale industry and the industrial SME sector. Consulting and services for strategic and operational planning round out DUALIS’s range of offerings.
The Dürr Group is a leading global manufacturer of machinery and systems with particular expertise in the technology fields of automation, digitalization, and energy efficiency. Its products, systems, and services enable highly efficient and sustainable manufacturing processes—primarily in the automotive industry, among manufacturers of furniture and wooden houses, as well as in the assembly of medical and electrical products and in battery production. In 2025, the Dürr Group generated revenue of just under €4.2 billion and currently has approximately 18,000 employees and 124 locations in 32 countries.
– – – – –
Further Links
👉 www.dualis-it.de
Graphic: DUALIS
