5G as a Success Criterion for Smart Intralogistics

Smooth communication between automated vehicles, warehouse management and control systems requires a stable communication environment and minimal delays in data transmission. Even the most modern fleet of Automated Guided Vehicles (AGVs) will remain inefficient if the infrastructure does not play along. "With this research project, we have not only driven forward developments in the field of 5G, we were also able to gain a lot of new insights using the campus networks, and on this basis we will be able to make even more targeted decisions in the future when it comes to setting up a fast and secure communication infrastructure," emphasizes Ansgar Bergmann, KION project manager for CampusOS. This is particularly necessary as efficient intralogistics is increasingly based on Industry 4.0 applications and the automation of logistics processes. Research projects such as the ARIBIC project , completed in 2024, in which digital twins of warehouses were created in real time, are rapidly accelerating this process.

Bergmann explains the significance of 5G using a simple example: "The capabilities of a high-end smartphone are very limited if I'm in a dead zone. Similarly, automated and autonomous vehicles are most efficient when stable network coverage is guaranteed." KION therefore invested in a 5G campus network as early as 2022 as part of the CampusOS project in order to test central applications such as the delay-free control of AGVs and the transmission of high-resolution video data in real time. High prices for the systems and the resulting low market penetration among customers as well as the lack of adaptation options for existing networks showed that this technology needs to be developed further.

The CampusOS research project, funded by the German Federal Ministry for Economic Affairs and Climate Protection, was designed to test the use of open, modular 5G campus networks for industrial applications. The project investigated specific details of how an open, modular 5G campus network must be structured so that autonomous vehicles can communicate smoothly not only in theory, but also in demanding everyday working conditions. The results showed that 5G is a powerful alternative to WLAN in intralogistics. This is because WLAN is more susceptible to interference, particularly due to the low system-related transmission power and the open frequency bands. "Above all, guaranteed bandwidths and the reliability of 5G make the difference," explains Bergmann. "Private 5G uses a frequency spectrum specially licensed for the user that is not publicly accessible. The use of network slicing or TSN (Time Sensitive Networking) approaches guarantees bandwidth for relevant infrastructures and enables the stable networking of numerous devices – from autonomous transport vehicles to handheld scanners and AI-supported camera systems."

The findings from CampusOS are groundbreaking for the entire industry, as Industry 4.0 concepts and machine learning require powerful data processes. For outdoor areas in particular, where WLAN is often not available, 5G could play a key role, for example in controlling automated guided vehicles. Although company-owned 5G networks are currently still cost-intensive, the use of open 5G campus networks in particular should lead to falling costs.

Bergmann draws parallels with the development of the smartphone: "Internet-enabled cell phones were initially very expensive to use. As the number of providers and users increased, the rates fell. We expect the same for 5G in industry." The aim of CampusOS was therefore also to provide a catalog of technical building blocks that make it easier to set up specialized campus networks, thereby facilitating access to the technology. But that’s not all: "What we have learned from this project will also form an important basis for further developments in the field of mobile communications, such as 6G or the new 26 GHz band." Above all, however, it will enable KION to offer customers an even better customized solution.