1.  Application Background & Challenges

With the advancement of Industry 4.0 and intelligent manufacturing, AGVs (Automated Guided Vehicles) and AMRs (Autonomous Mobile Robots) have become the core execution units in smart warehousing, flexible production lines, and unmanned logistics. These mobile devices must receive real-time dispatch commands, continuously report position and status data, and carry high-bandwidth services such as visual perception and edge computing — placing demands on the wireless network far beyond those of traditional industrial environments.

Four core challenges currently face AGV/AMR wireless communications:

● Seamless Roaming: Vehicles move continuously throughout a facility and must hand off between APs within 100 ms without any data interruption; failure triggers an emergency stop or mission failure.

● Interface Diversity: AGV controllers commonly use legacy industrial buses such as CAN FD, RS232, and RS485, which must be aggregated into an IP network for seamless integration with upper-level WMS/MES systems.

● High-Density Concurrency: Large warehousing sites may operate dozens to hundreds of AGVs/AMRs simultaneously; the network must support high-density access while maintaining low latency under heavy simultaneous traffic.

● Centralized AP Management: Large numbers of APs distributed across the facility must be configured, monitored, and upgraded uniformly to avoid the high operational cost of per-unit on-site maintenance.

2.  Overall Solution Architecture

PUSR IoT addresses the AGV/AMR scenario with a complete end-to-end wireless communication solution built around the AC200 Wireless Access Controller + AP520X Outdoor Wi-Fi 6 AP + USR-W650 On-board Industrial Wireless Client, covering the full link from cloud management to field terminals.

[Figure 1]  AGV Warehousing Scenario: USR-W650 On-board Terminal + AP520X Access Points — Collaborative Deployment

The overall architecture is divided into four layers from top to bottom:

● Cloud Management Layer: The PUSR Cloud Platform aggregates status data from all ACs, APs, and terminals, providing remote configuration, OTA batch upgrades, anomaly alerts, and historical log analysis.

● AC Control Layer: The AC200 centrally manages up to 200 AP520X units, uniformly pushes configurations, coordinates roaming handoffs, and provides PoE power — greatly simplifying AP deployment.

● Wireless Access Layer: AP520X units are distributed across warehouse rack tops or facility columns according to coverage requirements, forming a continuous Wi-Fi 6 coverage network under unified AC200 management.

● Terminal Device Layer: USR-W650 serves as the AGV on-board wireless terminal, converting CAN FD, RS232, RS485, and other control bus data uniformly into IP data streams and connecting to the AP network via Wi-Fi.

3.  Core Product Details

3.1  AC200  Wireless Access Controller (Centralized AP Management Hub)

The AC200 is an integrated wireless access controller from PUSR IoT that combines AP controller and PoE switch functionality in a single unit — the "brain" of the entire AGV wireless network. It centrally manages all AP520X access points, coordinates roaming handoff logic, and powers APs via PoE over a single cable for both data transmission and power delivery, dramatically reducing deployment complexity.

Centralized Management of 200 APs — Scheduling Hub for Large-Scale AGV Deployments

AC200 supports two network modes: in Router Mode (Gateway Mode), AC200 connects directly to AP520X units — suitable for small-scale AGV fleets with fewer APs; in Bypass Mode, AC200 connects to APs through a switch without carrying user data traffic, enabling management of up to 200 APs — ideal for large-scale distributed scenarios such as large warehouses and campuses.

Dual-Use PoE — Simplified AP520X Deployment & Cabling

AC200 features a built-in standard PoE module. All four LAN ports support 802.3af/at PoE output (48 V), with a maximum total power of 57 W and up to 30 W per port, over a cable distance of up to 100 m. Each AP520X only needs one Ethernet cable to receive both data and power simultaneously, eliminating separate power wiring and significantly improving installation efficiency.

Seamless Roaming Acceleration — Ensuring AGVs Stay Connected Across APs

AC200 features a built-in seamless roaming acceleration mechanism. Through centralized controller-side coordination, it ensures AGVs/AMRs remain online during AP handoffs. The controller maintains terminal association information for all APs and can proactively trigger roaming handoffs when a terminal reaches a coverage boundary. Combined with the <100 ms fast handoff on the USR-W650 terminal side, truly seamless roaming is achieved.

3.2  AP520X  Outdoor Wi-Fi 6 AX3000 Dual-Band AP (Wireless Coverage Infrastructure)

AP520X is a Wi-Fi 6 dual-band access point from PUSR IoT designed for outdoor and industrial environments. When used with AC200, it operates in thin AP mode — configuration and firmware are uniformly distributed by AC200, enabling zero-touch batch deployment. With 27 dBm high transmit power and IP67 protection, AP520X is the preferred wireless access infrastructure for AGV warehousing and outdoor campus scenarios.

[Figure 2]  AC200 + AP520X Centralized Management Deployment Topology (PoE Single-Cable Power + Data)

Wi-Fi 6 High Performance — No Speed Drop with Multiple Concurrent AGVs

AP520X supports Wi-Fi 6 OFDMA and MU-MIMO technologies, serving up to 256 terminals simultaneously per AP. Multiple AGVs can access the network simultaneously without channel contention, minimizing access latency. The maximum Wi-Fi 6 throughput of 2975 Mbps provides ample bandwidth for high-bandwidth services such as AGV visual data upload and LiDAR point cloud transmission.

27 dBm High Power — 1 km Coverage Reduces the Number of APs

AP520X transmits at up to 27 dBm, paired with two N-type external omnidirectional antennas (6 dBi) on each of the 2.4 GHz and 5 GHz bands, achieving a measured coverage diameter of up to 1 km. In large warehousing or outdoor campus scenarios, a single AP520X covers a larger area; combined with AC200, this significantly reduces the total number of APs required and lowers overall deployment cost.

IP67 Industrial Protection — Adapts to Harsh Deployment Environments

AP520X features IP67 waterproof and dustproof protection, an operating temperature range of ?40 °C to +70 °C, and built-in 2 kV surge protection, enabling long-term deployment in high-humidity and dusty warehouse environments, outdoor installations, and production corridors. It supports 802.3at PoE power input, and together with AC200's PoE output, a single network cable handles both data transmission and device power.

3.3  USR-W650  Industrial Wireless Client (AGV/AMR On-Board Terminal)

USR-W650 is the flagship on-board wireless terminal from PUSR IoT, developed specifically for the AGV and industrial robotics market. It highly integrates four key functions into a single industrial-grade unit: industrial Ethernet switch, CAN FD protocol gateway, serial server, and Wi-Fi wireless router — making it the core terminal device installed directly on the AGV chassis in the entire wireless communication solution.

Fast Wi-Fi Roaming — Seamless Handoff in Under 100 ms

[Figure 3]  USR-W650 Fast Wi-Fi Roaming Diagram (Handoff Time <100 ms, Seamless Between APs)

USR-W650 supports dual-band 2.4 GHz/5.8 GHz fast roaming. In conjunction with AP520X (managed by AC200), AGV AP handoff time is less than 100 ms. At vehicle speeds of 2–3 m/s, data loss during each handoff is negligible; the dispatch system perceives no network jitter and the AGV does not need to slow down or stop.

● Proactive Pre-Scanning: Evaluates nearby candidate APs before the current AP signal degrades, building a candidate list in advance.

● Fast Pre-Authentication: Completes target AP pre-association handshake before the handoff is triggered; the actual switch requires only a lightweight re-association.

● AC200 Coordination: The controller maintains the state of all network terminals and proactively pushes roaming recommendations to accelerate handoff decisions.

CAN FD High-Speed Interconnection — No Modification to Existing Control Bus

[Figure 4]  USR-W650 CAN FD High-Speed Interconnection Diagram (CAN FD → Ethernet/Wi-Fi/Modbus TCP)

USR-W650 features one built-in CAN FD interface, compatible with standard CAN 2.0A/2.0B, supporting multiple conversion modes, enabling wireless connectivity without modifying the existing CAN control architecture:

● CAN FD → Ethernet/Wi-Fi transparent transmission

● CAN FD → Modbus RTU/TCP gateway conversion

● Supports transparent with ID, standard protocol, and custom conversion modes

Multi-Interface Integration — One Unit Replaces Four Devices

USR-W650 integrates four major functions in a single industrial-grade unit, greatly saving installation space inside the AGV, reducing inter-device wiring, and lowering the overall system failure rate.

4.  How the Three Products Work Together

AC200, AP520X, and USR-W650 each play a distinct role in the AGV wireless communication scenario, collaborating closely to form a self-consistent, complete system:

● Deployment Phase: Engineers complete one-time configuration in the AC200 Web interface or PUSR Cloud Platform. AC200 automatically distributes Wi-Fi parameters, SSIDs, and roaming policies to all AP520X units in batch — no per-AP configuration required, greatly improving project delivery efficiency.

● Access Phase: When powered on, USR-W650 on the AGV automatically scans and associates with the AP520X with the strongest signal, connects to the facility network through that AP, and establishes a data path to the dispatch system.

● Roaming Phase: While the AGV is in motion, USR-W650 continuously monitors signal quality. When roaming conditions are triggered, it works with AC200's roaming coordination to complete the AP handoff within 100 ms — CAN/RS485 control data is uninterrupted.

● Management Phase: Operations staff use the PUSR Cloud Platform to remotely view the online status of all ACs, APs, and AGV terminals, push firmware updates in one click, and access historical logs at any time — no on-site operations required.

5.  Typical Deployment Scenarios

5.1  Large-Scale Smart Warehousing Center

In a large e-commerce warehousing center with an area exceeding 5,000 m2, dozens to hundreds of AGVs operate collaboratively. AP520X units are deployed at 30–50 m intervals on top of rack rows, managed by a single AC200 (bypass mode) covering the entire facility. Each AGV is equipped with USR-W650, which receives motion controller commands via CAN FD, connects barcode scanners via RS485, and reports cargo information to the WMS in real time. AC200's roaming coordination ensures AGVs stay connected throughout operations; the PUSR Cloud Platform provides centralized monitoring of all equipment.

5.2  Automotive / Electronics Flexible Manufacturing Line

In automotive component or electronics assembly lines, AMRs handle inter-process material delivery, frequently traveling between multiple workstations. AP520X and AC200 together provide precise roaming handoff coordination. USR-W650's RS485 interface connects RFID readers, its RS232 interface connects HMIs, and its CAN FD bus interfaces with drive controllers; all data is synchronized to the MES system in real time via Wi-Fi. SSL/TLS encrypted transmission protects production process data.

5.3  Outdoor Industrial Campus Cross-Zone Delivery

Between multiple buildings in an industrial campus, AGVs handle inter-zone transport of raw materials and finished goods. AP520X's 27 dBm high power and 1 km coverage diameter, combined with IP67 outdoor protection, significantly reduces the number of outdoor APs required. AC200 centrally manages AP520X units distributed across buildings in bypass mode; USR-W650 enables cross-building roaming, maintaining dispatch connectivity throughout.

6.  Summary of Core Solution Advantages