DÜRR AGV EcoProFleet

Smart industrial design meets automation

In order for the vision of lean, flexible and self-controlling production processes of Industry 4.0 to become reality, new automated intralogistics are needed. This task is performed by Automated Guided Vehicles, AGVs for short, which independently transport components, assemblies, raw materials or in this case: painted car bodies to the respective processing stations where they can be inspected visually.

Paint shops become flexible

With "EcoProFleet", Dürr Systems the market leader in paint finishing systems offers an AGV that has been specifically designed for use in painting lines. At first glance it differs from normal AGVs mainly in its low overall height of 335 millimeters. Thanks to this low-profile design "EcoProFleet" can interact directly with Dürr's modular workstation systems. "EcoProFleet" is able to pick up a completely painted car body using its fixing pins and transports it into the modular light tunnel for a final inspection of the paint quality.

Dynamically designed chassis

The design clearly distinguishes "EcoProFleet" from other AGVs. For example, the creative team at defortec has elegantly integrated the laser scanners into the corners of the vehicle’s chassis. The light strips that are used as directional indicators but also as status lights are placed inside the AGV’s corners as well. Although the chassis has a rectangular shape, it has a very dynamic effect - acheived by inclined surfaces between the corners.

Glass as a material with a double benefit

The real design highlight however is the glass surface precisely placed on the top side. Their transparency allows a view of the internal technology, the AGV presents itself open and not as a black box. To facilitate maintenance and reduce downtimes, defortec has ensured that the interior is easily accessible. Divided into four areas, the entire cover can be opened. The glass also protects the AGV - from being stepped on.

In the first test vehicles built by Dürr themselves, the upper side was made of a checker plate. A material usually used to cover floor areas visually encouraged people to walk on it inevitably provoking damage and in the end failure of the robot. Even large warning symbols could not neutralize the visual step-on-invitation of the sheet metal structure. Now, with the fragile-looking but in reality very stable glass surface, the problem has been solved. Defortec's intelligent industrial design makes targeted use of psychological effects like this. And anyway: Smart technology needs smart design.

Excellent innovation design

Defortec has been working for Dürr Systems for some time now. For example, the modular cabin system that now forms the framework for "EcoProFleet" was developed jointly.

The jury of the reddot design award also recognized the innovative nature of the industrial design of the "EcoProFleet" concept and awarded the vehicle the "best of the best" seal of quality in 2020. This is an award that Dürr Systems also deservedly received since the company's design-oriented engineering also contributed to achieving this high level of esthetic quality.

Project overview

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Good to know...

A small glossary intended to
simplify the understanding of design Glossary
"Design Freeze (Design einfrieren)"

Kommt aus dem Innovationsmanagement und ist eine Phase des Produktentstehungsprozesses. Bei einem Design Freeze wird das Design wird auf einem bestimmten Stand „eingefroren“. Das bedeutet sämtliche Designelemente können nicht mehr getauscht und verändert werden. Die Farbe, die Oberfläche und die Form liegen somit fest. Außerdem die Geometrie, Proportionen, die Funktionselemente und Flächen müssen zu diesem Zeitpunkt fest stehen und definiert sein. Es sollten spätere Änderungen vermieden werden, um Kosten und Zeit zu sparen und den Produktionsstart einzuhalten. Sollten doch konstruktive Änderungen nötig sein, müssen diese dokumentiert werden.


Ein Design Freeze beinhaltet folgende Schritte:

  • Die Kontrolle von der Form und den Funktionen
  • Die Ermittlung der Produktionsvorgaben
  • Die Abstimmung auf Produktionsvorgaben
  • Definitive Festlegung von Material, Oberfläche und Farben
    Visualisierungen. Das geschieht z.B. durch Renderings, Sketches, Storytelling und technischen Zeichnungen.
  • Die Finale CAD-Konstruktion-Daten.
  • Erstellung von Prototypen (Funktion, Ergonomie, Design, Interaction).