Architecture for two-level mobile robot control system for warehouse logistics

V.V. Shukhin, Z.L. Khakimov, M. A. Labazanov

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Abstract: The relevance of this work is driven by the growth of the warehouse robotics market and the need to combine intelligent functions with precise, deterministic control. A two-tier architecture for an autonomous mobile robot control system is proposed, separating cognitive (NVIDIA Jetson Orin Nano, ROS 2) and executive (STM32H743ZI, FreeRTOS) functions. A specialized data exchange protocol with integrity monitoring is developed. The proposed architecture ensures balanced distribution of the computational load and can be used to create high-precision mobile platforms for warehouse applications.
Aim. The research is to develop and mathematically justify such an architecture, evaluate its ultimate performance, and demonstrate its advantages through a comparative analysis with existing approaches.
Research methods. The following research methods are used in this study:

1. Mathematical modeling and calculations – formalization of models for assessing positioning accuracy using an extended Kalman filter, calculation of system timing parameters, and the probability of data transmission errors.

2. Simulation modeling – system verification in ROS 2 and Gazebo, assessment of dynamic accuracy and response time.

3. Algorithmic design – development of cascade PID controllers for motor control and an exchange protocol between architecture levels.

4. Comparative analysis – comparison of the characteristics of the proposed system with commercial analogues (MiR250, Fetch Freight 1500).

5. Experimental evaluation – Monte Carlo simulation to determine the root mean square positioning error, energy consumption and autonomy analysis.
Results. This paper presents an innovative two-tier architecture for an autonomous mobile robot (AMR) control system for warehouse logistics. The architecture divides the computational load between a high-level controller based on a NVIDIA Jetson Orin Nano single-board computer (4 GB) running the ROS 2 Humble operating system and a low-level controller based on an STM32H743ZI microprocessor (ARM Cortex-M7 core, 550 MHz) running the FreeRTOS RTOS. The high-level controller handles navigation using SLAM algorithms (based on the Ouster OS0-32 lidar) and global path planning, while the low-level controller provides precision motor control via cascaded PID controllers and data processing from Renishaw RESOLUTE absolute encoders with 26-bit resolution. This paper presents the developed binary communication protocol with integrity checking (CRC-16-CCITT), formalizes mathematical models for calculating positioning accuracy, and identifies critical timing parameters of the system. The estimated low-level control cycle time is 1 ms, and the average interprocess communication latency is 3.5 ms. The system demonstrates a theoretical positioning accuracy of ±2.1 mm using odometry and lidar sensor fusion. Simulation results indicate the feasibility of processing up to 15 target tasks per minute in a typical 10×10 m warehouse cell.
Conclusion. The proposed architecture represents a balanced solution combining high performance, determinism, and relative affordability, making it a promising foundation for the next generation of research and commercial warehouse AMRs.

Keywords: autonomous mobile robot, warehouse logistics, distributed control system, ROS 2, FreeRTOS, sensor fusion, PID controller, absolute encoders

For citation. Shukhin V.V., Khakimov Z.L., Labazanov M.A. Architecture for two-level mobile robot control system for warehouse logistics. News of the Kabardino-Balkarian Scientific Center of RAS. 2026. Vol. 28. No. 1. Pp. 102–116. DOI: 10.35330/1991-6639-2026-28-1-102-116

©   Shukhin V.V., Khakimov Z.L., Labazanov M.A., 2026

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Information about the authors

Vladimir V. Shukhin, Candidate of Technical Sciences, Associate Professor, Department of Automation of Technological Processes and Production, Grozny State Oil Technical University named after academician M.D. Millionshchikov;
100, Isaev avenue, Grozny, 364051, Russia;
shukhin86@bk.ru, ORCID: https://orcid.org/0009-0003-0273-0058, SPIN-code: 2895-3434
Zaur L. Khakimov, Candidate of Technical Sciences, Associate Professor, Department of Automation of Technological Processes and Production, Grozny State Oil Technical University named after academician M.D. Millionshchikov;
100, Isaev avenue, Grozny, 364051, Russia;
deffender_95@mail.ru, ORCID: https://orcid.org/0009-0007-1665-8631, SPIN-code: 3540-6580
Magomed A. Labazanov, Senior Lecturer, Department of Automation of Technological Processes and Production, Grozny State Oil Technical University named after academician M.D. Millionshchikov;
100, Isaev avenue, Grozny, 364051, Russia;
labazanov.90@inbox.ru, ORCID: https://orcid.org/0009-0005-9714-5146, SPIN-code: 5981-5217

Funding

The study was performed without external funding.