Motorized vs. Non-Motorized AGV Drive Wheels: Pros and Cons

Motorized AGV drive wheels provide active propulsion, precise speed control, and positioning accuracy, making them essential for autonomous navigation. Non-motorized wheels serve supporting, stabilizing, or load-bearing roles and cannot replace powered wheels in AGV motion systems. The choice is not about preference—it defines how an AGV moves, navigates, and performs under real operating conditions.

Below is a technical comparison based on AGV design, system integration, and long-term operational performance.

What Is the Difference Between Motorized and Non-Motorized AGV Wheels?

Motorized AGV wheels integrate a motor, gearbox, encoder, brake, and wheel assembly into a single unit that actively drives the vehicle. Non-motorized wheels—such as passive wheels or casters—rotate freely and rely on motorized wheels or external force to move.

In an AGV system, these two wheel types play fundamentally different roles.

Motorized AGV Drive Wheels

Why do AGVs require motorized drive wheels?

AGVs must move autonomously, follow programmed paths, stop at exact positions, and repeat movements reliably. Motorized drive wheels enable:

• Controlled acceleration and deceleration

• Accurate turning through differential speed control

• Encoder-based position feedback

• Integration with navigation and safety systems

Advantages

• High navigation accuracy

• Stable performance under dynamic loads

• Full compatibility with AGV and AMR controllers

• Support for braking and safety functions

Limitations

• Higher upfront cost

• More complex integration and commissioning

• Requires electrical and control system alignment

Typical applications

• All AGV and AMR propulsion systems

• Pallet movers and towing AGVs

• Precision positioning vehicles

Motorized wheels are the core motion components of any autonomous vehicle.

Non-Motorized AGV Wheels

What are non-motorized wheels used for in AGVs?

Non-motorized wheels are used for support, balance, and load distribution. They do not provide propulsion or steering.

Advantages

• Simple mechanical structure

• Low cost and easy replacement

• Suitable for stabilizing heavy loads

Limitations

• No propulsion or control capability

• Cannot contribute to navigation accuracy

• Increased wear if improperly loaded

Typical applications

• Support casters

• Balancing wheels in multi-wheel AGVs

• Auxiliary load-bearing positions

Non-motorized wheels complement, but never replace, motorized drive wheels.

Can an AGV Use Only Non-Motorized Wheels?

An AGV cannot operate autonomously using only non-motorized wheels. At least one motorized drive wheel is required to generate motion and enable control. Systems relying solely on passive wheels require external pushing or towing, which eliminates automation.

How Do Motorized Wheels Improve AGV Positioning Accuracy?

Motorized wheels use encoders and closed-loop control to track rotation, speed, and direction. This allows the AGV controller to correct deviations in real time. Non-motorized wheels provide no feedback, making them unsuitable for navigation or positioning tasks.

Impact on Load Handling and Stability

Motorized wheels are engineered to manage dynamic loads, including starting, stopping, and turning under full payload. Non-motorized wheels are designed primarily for static load support and must be carefully matched to avoid uneven wear or instability.

Maintenance and Lifecycle Cost Comparison

Which option has lower long-term cost?

Motorized wheels require professional maintenance but offer predictable wear and scheduled servicing. Non-motorized wheels are cheaper individually but may require frequent replacement if load distribution is incorrect.

In most AGV systems, optimizing the ratio and placement of motorized to non-motorized wheels reduces overall maintenance costs.

Motorized vs. Non-Motorized AGV Wheels: Key Comparison

FAQ: Common Design Questions

How many motorized wheels does an AGV need?

This depends on payload, maneuverability, and floor conditions. Common configurations include single, dual, or four motorized wheels.

Do non-motorized wheels affect AGV accuracy?

Indirectly. Poorly aligned or worn passive wheels can increase drag or vibration, impacting overall motion stability.

Can non-motorized wheels be upgraded later?

Yes, but converting passive wheels into motorized units requires structural and control system redesign.

Industry Insight from an AGV Drive Wheel Supplier

In real-world AGV projects, performance issues often arise not from motor failure, but from improper allocation between motorized and non-motorized wheels. Too few motorized wheels reduce traction; poorly selected passive wheels increase resistance and wear.

At Honest Edrive, we support OEMs and integrators by optimizing wheel layouts—matching motorized drive units with correctly specified non-motorized support wheels to achieve stable motion, accurate navigation, and long service life.

Understanding the roles, advantages, and limitations of both wheel types is essential for building reliable and scalable AGV systems.