Atlanta, GA - VisionNav Robotics, a global supplier of autonomous industrial vehicles and logistics automation solutions, has introduced an autonomous stacking system engineered specifically for large container environments where accuracy, stability and safety are paramount. Introduced at Modex 2026, the company's VNE40-66 Autonomous Precision Stacking Solution can stack 8.8-foot-wide cages weighing up to 6,150 pounds at heights of up to 22 feet - the market's first such solution to achieve such robust capabilities.

To achieve this level of performance with total stability and accuracy, the unit utilizes VisionNav's proprietary sensor fusion technology that provides millimeter-level precision compatible with various post types, ensuring each placement is exact despite differing container sizes or environmental conditions. Reliable and robust, the system carries a rated payload of 6,150 pounds, making it suitable for the exceptionally heavy, wide containers common in automotive and other heavy-duty settings.

Among the VNE40-66's most attractive features is its Smart Retry Functionality, which continuously monitors for misalignments and anomalies in real time; if misaligned containers, incorrect position posts or other adverse issues are identified, the system aborts and retries without requiring operator input. This dramatically reduces downtime, minimizes risk of product damage, and supports fully autonomous operation in high-throughput environments where human intervention would create untenable bottlenecks.

Technology-driven Safety Features

The VNE40-66 Autonomous Precision Stacking Solution's safety capabilities are as sophisticated as its stacking precision. This intelligent, context-aware safety envelope ensures that the system responds appropriately to real operating conditions rather than relying on static safety margins. For example, during straight-line travel, a dynamic brake zone scales to the size of the load being carried, with larger goods generating wider, deeper boundaries. Through corners and curves, zones reconfigure to match the vehicle's turning geometry.

A key differentiator of the VNE40-66 is its dedicated manual forklift fork protection system, which detects approaching forklift forks across three distinct scenarios. Critically, the solution can detect whether other vehicle forks are on the ground or lifted - a capability especially valuable in mixed human-robot environments. Dedicated protection zones are applied during the forklift lifting cycle itself, with distinct profiles for both empty and full load conditions. The module's protection zone geometry adjusts depending on whether the forklift is carrying a load, ensuring the right level of protection across various operational states.

"After years of working in real warehouse and manufacturing environments, one thing is clear: automation doesn't happen in isolation," said Ahmad Stokes, Senior Director of Sales at VisionNav Robotics. "You're always dealing with mixed traffic, especially manual forklifts, and something as simple as forks left on the ground can create serious risk. The VNE40-66's ability to detect those forks and respond in real time adds a critical layer of collision prevention, making automation more practical, flexible, and ultimately safer to deploy at scale."

VisionNav's VNE40-66 Autonomous Precision Stacking Solution's reliable detection system can identify obstacles as small as 4x4 inches. Equally important, its dedicated personnel protection functionality employs multi-layered 3D sensing to identify the presence of workers in the vehicle's operating area and respond accordingly.

A departure from conventional standalone 2D or LiDAR obstacle protection, the VNE40-66 integrates both into a single comprehensive safety system. A mechanical safety design ensures structural integrity throughout all operational scenarios, with safety lasers providing 360-degree assessment - a comprehensive awareness perimeter regardless of approach direction. Complementing these features, an auxiliary 3D protection system adds a dynamic layer of spatial intelligence based on real-time monitoring of the vehicle's maximum operating length and width.

About VisionNav Robotics
Headquartered in Atlanta, VisionNav Robotics is a global leader in autonomous industrial vehicles (AMRs/AGVs) and logistics automation solutions. Utilizing deep learning, environment perception and servo control technologies, VisionNav has developed nine product series to address full-stack material handling scenarios. With over 750 projects deployed across more than 30 countries, VisionNav is trusted by numerous Fortune 500 companies in industries such as automotive, food and beverage, chemical, pharmaceutical, and 3PL, enhancing operational safety, efficiency, and future readiness. www.visionnav.com.