A traffic management system for large and heterogeneous vehicles in narrow industrial environments
Authors: Alessandro Bonetti, Silvia Proia, Simone Guidetti, Lorenzo Sabattini
Abstract
The coordination of Automated Guided Vehicles (AGVs) in high-density industrial environments represents a critical challenge within Logistics 4.0, as traditional traffic management methods often lead to inefficiencies caused by negotiation-based priority assignment. To overcome the resulting limitations, this paper presents an innovative AGV traffic management system based on a Lifelong Multi-Agent Path Finding (L-MAPF) algorithm operating on roadmaps generated with Non-Uniform Rational B-Splines (NURBS) curves. The approach guarantees locally optimal coordination and ensures safe operation of large and heterogeneous AGVs. Building on this concept, the proposed framework integrates a modified version of the Bounded Horizon Conflict Based Search (CBS) technique within a Rolling Horizon Conflict Resolution strategy, utilizing an extended time horizon for each agent to enable effective conflict resolution in corridors identified by a topological map. In contrast to state-of-the-art methods for AGV fleet traffic management, the proposed solution is designed for real-world, non-standardized (i.e., non-grid-like) industrial settings characterized by narrow bidirectional corridors and high-traffic density, where AGVs of various sizes and capabilities operate simultaneously. Key contributions include an anytime conflict resolution strategy with adaptive time horizon regulation, an execution layer for safe and standard-compliant interaction with real AGVs, and an advanced mechanism for deadlock detection and resolution. Experimental results obtained in realistic industrial environments demonstrate higher throughput, with improvements of up to 11% over a conventional rule-based traffic management system, a state-of-the-art industrial method, and a priority-based L-MAPF variant, while maintaining continuous operation and improved efficiency.
Automatic Guided Vehicles (AGVs) substantially boost warehouse throughput, but routing large-scale AGV fleets remains challenging. Classical Multi-Agent Pathfinding solvers suffer from exploding combinatorial complexity and super-quadratic runtime, while relying on idealized grid or piecewise-linear motion models that mismatch real-world kinematics. Recent Reinforcement Learning (RL) solutions improve flexibility via decentralized agent policies but depend on discretized spatiotemporal representations, require millions of episodes to converge, and incur full-map observation at every step, which leads to large models, slow convergence, and high inference latency that violates real-time industrial control constraints. To address these bottlenecks, we propose HiRAD, a hierarchical RL framework for continuous-space AGV routing with real-time guarantees: (1) a step-level spatiotemporal representation that translates continuous motion into a differentiable RL problem, (2) a hierarchical strategy that splits heading choice from velocity control to reduce the action space, and (3) an asynchronous event-driven decision pipeline that lowers inference complexity from O(n^2) to O(n) and cuts per-step latency by as much as 71 percent. Across random graphs and two warehouse maps, HiRAD reduces makespan by 45 percent to 63 percent and shortens end-to-end runtime.
Multi-agent pathfinding (MAPF) under one-shot planning is a core component of warehouse automation, yet classical formulations typically assume four-connected 2D grids with unit-time moves in four directions. To fill reality gaps while still being trackable with discrete combinatorial search, this work proposes a more practical counterpart tailored to differential-drive AGVs. We term this multi-agent warehouse pathfinding (MAWPF), featured with four constraints: (i) agent actions are restricted to straight motion and in-place rotation; (ii) rotations require multi-step costs; (iii) acceleration and deceleration are considered, and; (iv) follower collisions are prohibited to prevent rear-end crashes. To solve MAWPF efficiently, we adapt representative suboptimal MAPF algorithms-PP, LNS2, PIBT, and LaCAM-and conduct comprehensive benchmarking. Our experiments reveal that PP and LNS2 struggle to solve instances with many agents, while PIBT-based approaches achieve preferable scalability with increased solution cost. We believe that these constitute an important step toward adapting classical gridworld MAPF to operational warehouse setups.
Coordinating autonomous vehicles at unsignalized intersections remains a critical challenge for multi-agent reinforcement learning (MARL) systems, which typically struggle with combinatorial action spaces, reliance on privileged information, or rigid agent designs. We propose Master-Agent Proto-plan System (MAPS), a hierarchical deep reinforcement learning (DRL) architecture in which a centralized Master agent generates a compact, continuous embedding, denoted as proto-plan, that encodes a global coordination strategy. Decentralized Worker agents integrate this embedding with local observations to execute vehicle-specific control, decoupling strategic intent from tactical execution and enabling independent optimization of each module. As a proof-of-concept evaluation of this coordination mechanism, we test MAPS across 72 intersection configurations in HighwayEnv. MAPS achieves collision-free navigation while significantly reducing average travel time, outperforming state-of-the-art baselines. The learned proto-plans further exhibit robust generalization: a system trained with three agents achieves a 94% success rate when deployed zero-shot to five-agent scenarios, confirming that proto-plan-based hierarchical learning provides a promising framework for multi-vehicle coordination.