Tag: forklift technology|materials handling|safety

Since their introduction in 2021, the latest electric counterbalance trucks from Linde Material Handling (MH) have been setting new standards with regard to ergonomics, visibility, safety and energy efficiency. Now, the Linde E25 to E35 models are also available in explosion-proof versions.

Operators can thus benefit from the extensive range of advantages offered by these series-production trucks. The vehicles for ATEX zone 2/22 are already available, with the versions for zone 1/21 to follow in mid-2023.

It was one of the crowd-pullers at the Dangerous Goods/Hazardous Substances trade fair in Leipzig at the beginning of November: the new Linde E25 to E35 EX electric forklift truck for ATEX zone 2/22. With the models of this series, the fundamentally improved generation of Linde counterbalance trucks is now also available for use in hazardous areas.

Close collaboration

“The close collaboration between series and Ex truck development at Linde Material Handling has proven its worth once again,” emphasizes Elke Karnarski, Product Manager Ex-Proof Trucks. The design of the chassis, cab and mast provides an optimal view of the vehicle, load and working environment, thus serving both increased handling performance and greater operational safety. Additionally, drivers benefit from an optimized operator’s workplace which is even more generously dimensioned than in the previous models and offers more headroom, for example.

“Thanks to the complete integration of the explosion protection measures, the advantages of the series-production trucks are fully retained for all ATEX zones,” affirms Karnarski.

At the same time, operation in hazardous environments is taken into account. Protection against static charge is provided by plastic trim, floor mats and tires, as well as seat upholstery and armrests made of dissipative material. For the first time, the front, rear and roof wipers for zone 1/21 are electrically operated as standard. As with the standard vehicles, drivers of explosion-proof models can read important information – such as the battery charge status, error codes or when the next service is due – on a 3.5-inch display (standard for zone 2/22) or the generous 7-inch TFT colour display (optional for zone 2/22, standard for zone 1/21).

Safety-relevant values, such as the temperature of various components, are also monitored and alerts are shown on a separate display. Additionally, the EX-Monitoring app provides the driver with specific recommendations for action such as letting the vehicle cool down for 15 minutes, for example. The app also enables predictive maintenance, by way of monitoring safety-critical wear parts and prompting the customer at an early stage to schedule a service appointment.

Comfortable, economical, safe and agile

In addition, the driver’s workplace is largely decoupled from the drive unit and mast, and an elastomer ring bearing is used for shock absorption on the front axle. This is particularly noticeable when driving over thresholds, guide rails or uneven ground, as it makes driving more comfortable and also safeguards the operator.

Efficient motors ensure reduced energy consumption. In turn, the electronic temperature monitoring system on the traction motors, which is linked to a safety warning and shutdown function, is a typical explosion-protection feature. Furthermore, all electronic controls, sensors, fuses and relays are centrally located in a pressure-resistant control housing, which is integrated into the rear of the vehicle for easy servicing. For fast, convenient charging of the lead-acid battery, optional access is provided via the rear of the vehicle.

Another special feature of the new explosion-proof E-Trucks is the great number of optional assistance systems and lighting solutions. As with the standard trucks, customers can choose from many equipment variants. Both LED headlights, BlueSpot, LED strips and VertiLight are available in non-sparking versions or as sealed components. The same applies to assistance systems such as the Linde Load-Assist, Safety Pilot, electronic seat belt monitoring and Linde Safety Guard. Added to this are the benefits of the Linde:connect fleet management solution with access control and electronic damage monitoring. The data transmission unit fitted as standard makes the explosion-proof trucks fit for digital logistics processes such as software updates.

Explosion protection from Linde

With the new Linde E25 to E35 EX E-Trucks, customers also receive qualified customer service, a 24/7 supply of standard and ATEX spare parts, as well as the respective ATEX certificates and detailed operating manuals, in addition to individual vehicle configurations.

 

 

Unfortunately, no matter where you go in the world, forklift-related workplace accidents are far too common. Recent events from around the globe demonstrate this unsettling fact.

• In the United Kingdom, a reversing forklift at a goat milk producer struck and killed a woman, resulting in a £200,000 fine.
• In Canada, the Minister of Labour is investigating the death of a worker struck by a forklift at an Ontario steel company.
• In Singapore, 3 out of 20 workplace fatalities so far this year have involved forklifts.

In the UK, forklifts account for more workplace accidents than any other machine, and 57% of all people injured by forklifts in the UK are pedestrians. In the US, the Occupational Safety and Health Administration estimates that if companies implement more stringent safety and training policies, forklift accidents could be reduced by 70%.

As the statistics and recent forklift accidents attest, any workplace that requires pedestrians to work near mobile equipment, like forklifts, must take pedestrian safety seriously and implement protective measures to keep their workers safe.

Keeping workers safe

SEEN Safety has addressed the persistent global issue of pedestrian safety head-on with its world-class IRIS-860 sensor. Through cutting-edge technology, their sensors have improved workplace safety for countless pedestrian workers around the globe who work in close proximity to forklifts and other mobile equipment.

SEEN works with companies in various industries where people and material handling machines work closely together – such as distribution centres, manufacturing, and logistics warehouses. They make sensors designed to detect when an employee has entered a critical area around mobile equipment like forklifts or wheel loaders. If a worker enters the area behind reversing equipment, the IRIS-860 sensor will audibly alert the driver to their presence.

SEEN’s sensors are simple to use. With the IRIS-860 sensor, workers do not need a complicated battery-operated transponder. Instead, the sensor identifies workers by transforming one of the most commonly used pieces of personal protective equipment, the high visibility vest, into part of an active safety system that is immediately effective and easier to implement than other options on the market.

The hard work of detection is done by SEEN’s infrared sensors, which work well beyond what an optical camera can ‘see’ in the visible light spectrum. SEEN deliberately uses infrared for detection, it is extremely reliable regardless of dust & dirt, weather and variable lighting – conditions commonly encountered in materials handling operating environments. Failure to detect reliably may be ok if people aren’t close to the machine when it’s operating, but it’s crucially important when a person enters the high risk zone behind a reversing machine.

In addition the sensors can be configured to meet the requirements of a specific worksite. Often, the operator is focused on their load which is usually in front of them creating a blind spot behind the machine, this is the area where pedestrian collisions can be the most catastrophic. SEEN’s sensors are designed to be configured to target that area precisely and reliably, focusing on the detections that really matter and minimising nuisance alerts.

The system is effortless to use, requiring zero specialist knowledge to install or set up, and always offers reliable protection, regardless of conditions. The sensors are also significantly more cost-effective than other alternatives, making it possible to spread them across your entire mobile equipment fleet.

 

Forklifts and other industrial trucks have become essential work equipment in logistics and warehousing. However, the risks associated with using forklifts are often underestimated. According to data from the German Social Accident Insurance (DGUV), more than 13,500 accidents resulting in personal injury and involving forklift trucks were reported in 2020 alone.

To avoid accidents, the drivers must constantly have the entire area around the forklift in view while driving and manoeuvring. Many drivers are under constant stress, which impairs their performance and often leads to driving errors. This is in addition to health problems from constantly turning their heads while driving backwards.

A new multicamera-based collision warning system from Bosch helps minimise the risk of accidents and reduce stress for drivers by improving the general view around the entire vehicle and actively warning the driver of impending collisions.

“With this system, we are making an important contribution to improving the level of safety when using forklifts and reducing the health-related strains for the drivers,” says Stefan Schenk, who is responsible for the Off-Road operating unit at Robert Bosch GmbH.

Multicamera system with active warning feature

The new assistance system comprises four compact near-range cameras and a control unit that creates an all-around view of the vehicle’s surroundings and displays this to the forklift driver on a monitor. Depending on the driver’s current information requirements, different views can be selected and shown on a display in full-screen format or in a split-screen layout. Additionally, the driver can choose from a variety of viewing modes like overlay of the driving trajectory or virtual camera panning.

The visual assistant presented at LogiMAT 2019 already ensures good all-round view even in blind spots, when the driver’s view is blocked by the load on the fork. With the expansion, the system now additionally warns of stationary or moving objects in the vicinity of the vehicle in dangerous situations with a colour marking on the monitor and an audible signal.

To achieve this, three characteristic and particularly dangerous driving scenarios were identified and corresponding use cases for the warning feature were derived. When driving in an aisle or past rows of shelves, the forklift driver is shown anyone kneeling, standing, or moving in front of or alongside the vehicle. If the system detects that a junction is approaching, it switches to intersection mode and additionally warns the driver of people or vehicles approaching from the side. A further benefit of the new assistance system is the warning feature that assists the driver when handling storage items. The detection is then aimed at people moving relative to the vehicle at a distance of 4m.

Object recognition with neural networks

To enable the system to reliably detect impending collisions and only provide warnings for relevant accidents risks, two analysis methods, object detection and object recognition, are combined. With object detection, the system logic decides whether or not an object is relevant to the collision warning on the basis of characteristic movements. With object recognition, the decision is made based on the shape of the object. To do this, the image of the object is automatically compared to stored image patterns.

“This is done by what are known as neural networks, a software architecture from the field of artificial intelligence, which are trained to recognise specific visual patterns. Merging the two measurement principles ensures that the three situations with a potentially critical accident risk are fully covered by the collision warning and both stationary and moving objects, for example, are detected,” says Schenk.

Ultrasonic sensor technology for working platforms

Bosch launched two versions of the 24V ultrasonic sensor system for near-field monitoring of the working area at the beginning of January. The ultrasonic sensors can be used to secure blind spots, such as a work cage on aerial work platforms. Although both 24V systems feature identical hardware, there are differences when it comes to the processing of the sensor data and thus the functional scope of the different versions.

While the basic system simply measures the distance of a specific obstacle, the high-end solution also features object localisation. Bosch designs assistance systems and functions for industrial trucks, but also for other industrial and off-highway applications, such as construction, agricultural, and municipal vehicles, to be tailor-made for their specific applications.

The Linde Motion Detection assistance system provides even better protection for pedestrians in warehouse environments as it is capable of detecting movement behind a stationary truck. In such cases, reversing is prevented and a warning signal sounded. Both employees and management benefit from this effective accident prevention system: The health of everyone present in the warehouse is better protected, the forklift driver’s job becomes easier, downtime or disruptions to operations are prevented to the greatest possible extent and, as a result, productivity is improved.

Linde MH is initially offering the sensor-based solution as an equipment option for the company’s new series of counterbalanced trucks. A retrofit solution, which will also be suitable for use on other makes of forklift, is to follow shortly.

Occupational safety and health protection are top priorities in many companies today. One of the most critical situations involving forklift trucks and pedestrians is the loading and unloading or picking up and putting down of loads. “If there are people behind the forklift when it starts reversing, an accident can quickly occur. Causes often lie in the behaviour of the people involved,” explains Fabian Zimmermann, Product Manager Safety.

“Pedestrians are inattentive and believe that the forklift driver can see them. Moreover, they do not expect that a forklift standing in front of a rack or in the block storage area could suddenly reverse. If, in addition, the driver is unwary for just a short moment and forgets to look over his shoulder, this can have serious consequences.

“In addition, the view to the area behind the vehicle can be obscured by blind spots, stored goods or racks. And the risk of accidents increases the more industrial trucks, pedestrians or even cyclists are present in logistics areas.”

Innovative technology

The Linde Motion Detection assistance system helps prevent such dangerous situations by warning both the forklift driver and any persons in the rear working area. A motion sensor reliably detects any movement behind the stationary vehicle, no matter the prevailing lighting conditions – regardless of whether the movement is triggered by people or other vehicles. In this case, the system automatically prevents or stops the approaching truck from reversing and the driver is alerted to the danger by a warning on the display.

In addition, the assistance system optionally sounds an acoustic signal to draw the attention of passers-by to the dangerous situation that has arisen and to trigger learning effects for everyone involved. To be able to continue driving after the warning has been issued, the driver has to actively put the accelerator pedal back in its starting position, which further increases safety.

Particularly in challenging working environments, such as poorly lit parts of the warehouse or areas where visibility is poor for structural reasons, the assistance system is an effective support and a relief for the driver. The detection area can be adapted to the respective operating and ambient conditions, which ensures a high degree of flexibility. In this way, critical situations are defused and unnecessary warnings prevented.

Linde Motion Detection is part of Linde MH’s comprehensive safety portfolio. With standard and optional assistance systems, such as the Linde Safety Guard or the Linde Safety Pilot, as well as consulting services, the company supports its customers in safe and efficient goods handling.

 

Hamburg-based intralogistics supplier STILL recently presented a webinar highlighting ways in which it has harnessed technology to help make the warehouse workplace safer.

In Germany alone, more than 20,000 reportable occupational accidents involving forklift trucks and warehouse equipment occurred last year. So much for the bad news. The good news: there are effective assistance systems that help prevent such accidents. STILL presented some of these innovative safety solutions in a webinar entitled Safe around the warehouse with industrial trucks.

To demonstrate where hazards lurk in the warehouse, Jürgen Wrusch and Janos Poppe took the webinar participants on a virtual warehouse tour. On the way, the two STILL experts explained that each warehouse has specific features and, as a result, an individual risk ranking.

Access and usage control

As early as at the beginning of the shift, hazards may arise from willful or negligent misconduct. For example, when vehicles are used without permission. This could be people who either do not have a driving license or whose driving ability is impaired. Or those who – without thinking of the consequences of their behaviour – want to use damaged vehicles or vehicles unsuitable for the task.

“Each of these reasons conjures up incalculable dangers,” emphasised Poppe. This can be remedied by systems that ensure that only competent operators use a suitable vehicle in proper technical condition. One of these systems is the pre-shift check feature of the STILL Easy Control on-board computer: before the start of each shift, or at user-defined intervals, drivers must confirm the vehicle’s operability via the on-board computer before they can operate the vehicle with all its functions.

STILL’s FleetManager access control system also offers a comprehensive suite of reports and telematics applications that can be used to monitor the use of trucks and drivers on the site. Acceleration sensors can also be used to monitor the driving style of the operators and – if necessary – intervene in the vehicle control.

“The sensor detects mechanical shocks and immediately generates a speed reduction. Road hogs whose wanton misbehaviour poses a danger to people and equipment are thus quickly unmasked and slowed down,” says Poppe.

Collision accidents

After successful access control, movement through the warehouse begins. From this moment on, there is a risk of collisions with other people or vehicles. “One way to prevent this is to use visual warning signals. These significantly increase the perceptibility of the vehicles,” explained Wrusch to the webinar participants.

A proven solution for this is the STILL warning zone light. The optional lighting equipment acts as a visual warning for pedestrians and other drivers in the immediate vicinity by projecting luminous strips onto the side of the hall floor next to the vehicle. This makes the STILL warning zone light a good complement to the STILL Safety Light. This projects blue light dots onto the ground at a distance of approx. 5m in front of and behind the vehicle, which warn of the approaching vehicle and can thus prevent an imminent collision.

A big step towards completely avoiding collision damage to people and vehicles are radio-based safety systems.  “The basic principle of these systems is to establish bidirectional communication via radio waves between vehicles, pedestrians and stationary equipment even without visual contact. For this purpose, this equipment as well as all pedestrians and vehicles are equipped with radio modules,” explained Wrusch. With their help, vehicle control can take place automatically in danger zones, for example by reducing the speed or braking the vehicle if there is a risk of collision.

Tipping accidents

Whenever the forklift truck is in a hurry on its way to the next task, the top risk looms: a tipping accident. “These occur with heavy counterbalance trucks as well as with pallet trucks. The frequent cause is excessive cornering speed,” recounted Poppe.

However, STILL has a suitable remedy for this risk, too, in the form of Curve Speed Control. The steering angle-dependent speed limitation reduces a possible tipping accident by ensuring an appropriate cornering speed. This assistance function is available for various forklift trucks and warehouse equipment and automatically regulates the travel speed depending on the steering angle. This means that the driver does not have to worry about speed when cornering. The vehicle automatically brakes exactly to the point where the operator is safe and at the same time as fast as possible when cornering.

Tipping accidents also occur when drivers overestimate the load capacity of their equipment. If there is too much load on the front of the forks, the truck tips over into the racking. To prevent this from happening, STILL has developed the Dynamic Load Control assistance system. This system limits the lifting height in relation to the load weight and thus prevents the truck from being overloaded.

Wrusch: “The result can be described like this for counterbalance trucks: The higher and heavier the load, the slower the lift. A very effective assistance system that not only makes storage at great heights much easier, but also considerably safer.”

Another innovative system for accident prevention is the Active Load Stabilisation (ALS). An automatic compensation pulse quickly and effectively stops the mast vibrations that occur at great heights, which – in addition to the safety benefit – also reduces the waiting time at the racking up to 80%.

Conclusion

The vision of accident-free intralogistics seems within reach, as the results of the STILL webinar showed. In order to make this a reality, however, not only innovative technical solutions for trucks are needed, but also effective training concepts for warehouse employees to enable them to handle these trucks safely and responsibly.

This is also the purpose of the website specially created by STILL on the subject of safety: www.still.de/safety. Even if the ever more reliable technology can take many decisions away from the operating personnel: industrial trucks are – and will remain in the future – complex tools which safe operation must be properly learned.