Cross-Floor Operations: How Autonomous Forklifts Integrate Seamlessly with Elevators

 


As smart warehouses continue to evolve, one challenge remains particularly complex — moving goods between floors efficiently and safely.

In traditional logistics environments, forklift operators manually drive into elevators, wait for doors to open and close, and unload at the next level. It’s a slow, repetitive, and sometimes risky process.
But as autonomous forklifts (AGVs and AMRs) gain traction, a new frontier of automation is emerging — cross-floor operation via elevator integration.

In this post, we’ll explore how autonomous forklifts communicate with elevators, what technologies make this possible, and why it’s a major step toward truly vertical warehouse automation.

The Multi-Floor Challenge in Modern Warehouses

Many manufacturing and logistics facilities are now building upward instead of outward.
Urban factories and e-commerce distribution centers often rely on multi-floor warehouse layouts to maximize space.

However, this creates a new bottleneck:
If forklifts can only operate on one floor, inter-floor transport still depends on manual work — limiting automation benefits.

Some common issues include:

  • Labor bottlenecks during floor-to-floor transfers

  • Delays in material handling and order fulfillment

  • Higher risk of collisions or human error inside elevators

The solution?
Fully autonomous forklift elevator integration, where robots can call, enter, and ride elevators independently.

How Autonomous Forklifts Integrate with Elevators

Successful cross-floor operation depends on seamless communication between three systems:
the forklift, the elevator control unit, and the fleet management platform.

Here’s how it works in real-world smart warehouses:

1. AI-Based Elevator Recognition

Using laser SLAM navigation and vision sensors, the forklift identifies elevator doors and positions itself precisely in front of them — no human alignment required.

2. Automatic Lift Calling

Through Wi-Fi or Ethernet, the forklift’s control system sends a digital signal to call the elevator.
The AI fleet management software determines which elevator is available and assigns it automatically.

3. Smart Communication with Elevator PLC

Once the lift arrives, the forklift communicates directly with the elevator’s PLC (Programmable Logic Controller) to trigger door opening and ensure safety checks.

4. Inside-Elevator Navigation

While inside, onboard IMU sensors and laser localization help the forklift maintain stability and orientation.
When the elevator reaches the target floor, it exits automatically and resumes its task — no pauses, no supervision.

5. Centralized Monitoring and Traffic Control

Every elevator call, movement, and status update is monitored in real time by the central AI fleet management system, which schedules traffic and avoids congestion between robots.

Key Benefits of Cross-Floor Automation

  1. True 24/7 Logistics Automation
    Forklifts can move between floors autonomously, reducing human intervention to zero.

  2. Improved Safety
    No operators ride elevators with machines, minimizing accident risk.

  3. Higher Throughput and Utilization
    Continuous movement across floors improves efficiency and task turnover.

  4. Smarter Elevator Scheduling
    AI manages elevator priority to prevent waiting queues or idle time.

  5. Scalability for Vertical Warehouses
    New floors or elevators can be added to the network with minimal reconfiguration.

Technical Considerations Before Deployment

Before implementing autonomous forklift elevator integration, make sure your infrastructure supports it:

  • The elevator must allow remote API or PLC communication (e.g., Modbus or Ethernet).

  • The cabin dimensions should fit the forklift with safe clearance.

  • Stable wireless connectivity (Wi-Fi or 5G) across floors is critical.

  • Emergency buttons and manual overrides must remain accessible for compliance.

Reeman’s engineering team provides full support—from elevator interface adaptation to signal debugging and safety validation—ensuring smooth multi-floor operation for any facility layout.

The Future of Vertical Automation

Cross-floor operation represents the final piece in the automation puzzle.
By integrating autonomous forklifts with smart elevators, factories and warehouses can achieve end-to-end vertical logistics — completely unmanned, efficient, and continuous.

Reeman’s AI-powered autonomous forklift fleet already operates across multi-floor facilities worldwide.
With SLAM navigation, real-time fleet coordination, and elevator system integration, Reeman helps enterprises unlock a new level of productivity in smart logistics.

Article Source: Reemanbot – Smart Logistics Robotics Solutions

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