AMR & AGV Toppers (Top Modules): Conveyor, Lift & Pallet Solutions

 

Engineered for safe, repeatable transfers with standard or custom options for your line.

 

Boost throughput and reduce manual handling with plug-and-play AMR and AGV toppers (top modules) that load, unload, lift, and position your product, including totes, cartons, pallets, and carriers, with precise docking at stations, cells, and work centers. Direct Conveyors designs and builds conveyors, lifts, risers, pallets, and specialty top modules that integrate cleanly with your AMR fleet and the surrounding conveyor or workstation equipment.

 

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At a glance

• Topper types: Motor-driven roller and belt conveyors, lifts and risers, scissor lifts, pallet movers, specialty and 2-bar lifts
• Use cases: Autonomous pick and drop, cell infeed and outfeed, station height changes, work-in-process loops, fork-truck handoff
• Platforms: Integration options for major AMR brands, including Omron, Kuka, MiR, OTTO and more
• Delivery: Standardized designs with custom options and application engineering support

 

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What is an AMR or AGV Topper (Top Module)?

A topper, also known as a top module, is the load-handling attachment mounted on the AMR or AGV, such as a conveyor or lifter, that enables the robot to safely and repeatedly pick up, move, and set down goods. Without the topper, an AMR is just a mobile base. The topper adds functions such as conveying, lifting, queuing, and docking, making the robot useful in real material-flow tasks.

 

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Topper Types and When to Use Them

Conveyor Toppers (Roller and Belt)

Best for: Automated transfers of totes, cartons, carriers, bins, and pallets between the AMR and a conveyor or station.

• Motor-Driven Roller (MDR): Positive control, bi-directional transfer, zoning, and gentle start and stop for rigid bottoms such as totes, pallets, and trays
• Belt (Flat or Modular): Full-surface support for smaller, irregular, or soft-bottom items and consistent contact where rollers are not ideal
• Options: Side guides, end stops, load presence sensors, barcode or ID readers, integrated E-Stops and guarding
• Handshake controls: Coordinated transfer signals with the receiving station for safe, predictable motion

Typical applications: Line infeed and outfeed, kitting, buffer moves, cell tend-return, cross-aisle bridging, and automated pallet exchange when paired with the right station

 

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Lift, Riser and Scissor-Lift Toppers

Best for: Height changes between floor, cart, machine bed, or station deck, ergonomic presentation, and pick and drop from variable elevations

• Travel: Application-specific vertical stroke for precise pick depth or station alignment
• Sensing: Upper and lower limits, position feedback, load confirmation
• Safety: Mechanical locks, guarding, and interlocks for service mode

 

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Pallet Movers and Heavy-Duty Handling

Best for: Pallet or heavy load transport between automated stations, pallet racks, or stretch wrappers

• Decks: Roller or modular-belt with heavy-duty frames, configurable deck sizes
• Workflow: Pick and drop from floor stands, conveyor accumulation, or fork-truck handoff at a guarded station
• Add-ons: Pallet centering, stops, and pallet-type specific tooling (EU or NA pallet features)

 

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Specialty and 2-Bar Lifts

Best for: Entering beneath a carrier or pallet to raise and carry when conveyors are unsuitable

• Use cases: Rigid carriers, pallets with adequate entry gaps, fixtures requiring underside engagement
• Tooling: Custom bars or fingers, sensor sets, and anti-drift features to suit your carrier design

 

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AMR Platform Compatibility

We design toppers to integrate with leading AMR platforms and their station ecosystems, including Omron, Kuka, and OTTO families. Integration details such as mounting, power, I/O, and safety are model-specific. Our engineering team can help validate docking accuracy, clearances, and control handshakes for each deployment, ensuring seamless integration.

Need an Omron-specific build? Explore our Omron Toppers ›
Building the full workflow? See AMR Stations ›

 

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Safety, Controls and Docking Confidence

• Handshakes and Interlocks: Station-to-topper signal exchange for ready, permit, transfer, complete, with timeouts and safe state on error
• Sensing: Load presence, zero-speed, deck alignment, and obstruction detection as required
• Emergency Stops and Guarding: Integrated E-Stops, guarding, and labeling aligned to cell risk assessments
• Maintenance: Service access, status lights, and diagnostic points built in

 

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Stations and Workflows (Complete the Loop)

Pair toppers with fixed stations, over and under accumulators, side-by-side loops, or on-the-fly gates to create reliable, operator-safe handoffs. Typical patterns:

• Fixed pick and drop for queuing and fork-truck handoff
• Over and Under for space-efficient buffer and robotic cell service
• Side-by-Side for circulate-and-return workflows

Explore AMR Stations › to see common layouts and options.

 

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Specifications at a Glance

Final dimensions, payload, and power vary by model. Your application engineer will supply a spec sheet with your quote.

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Industries and Use Cases

• Automotive and General Manufacturing: WIP movement between cells, line-side replenishment
• Electronics and Consumer Goods: Small-container flow and kit delivery
• Food and Beverage or Pharma: Packaged goods and clean-design options
• Logistics and Distribution: Tote or carton conveyance and pallet exchange

 

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Why Direct Conveyors

• Conveyor Expertise: Decades of conveyor and station experience, we design the entire handoff, not just the topper
• Standard and Custom: Start with proven modules, then tailor mounts, decks, sensors, and logic to your process
• Speed to Value: Standardized designs, application engineering, and scalable deployment support

 

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Frequently Asked Questions

What is the difference between a topper and a top module?
They are two names for the same thing, the load-handling module mounted on the AMR or AGV, such as a conveyor, lift, or pallet tool.

When should I choose roller versus belt on a conveyor topper?
Usea  roller for rigid bottom,s such as totes, trays, and pallet,s with zoned control. Choose belt for small, irregular, or soft-bottom items that need full-surface support.

How does docking stay safe and repeatable?
The station and topper exchange a handshake (ready, permit, transfer, complete), confirm alignment and load presence, and time out to a safe state if needed, supported by guarding and E-Stops.

Can you match our AMR brand or model?
Yes. Tell us your platform, product sizes, and weights, and station heights. We will specify the correct mount, power, and I/O.

Do you supply the stations too?
Yes. See AMR Stations › for fixed, ove/ under, side-by-side, andpick-and-dropp stands.

 

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Ready to Move Product Autonomously and Safely?

Let us design your AMR topper and station loop.
Call: 1 317-346-7777 · Email: sales@directconveyors.com · Contact Us ›