In narrow-aisle warehouses multidirectional forklifts often operate with minimal safety distances. Collisions with protruding loads pose a constant safety risk. To effectively minimise this risk, Hubtex has developed a patented ‘Clear Aisle Assist’: a system of laser sensors that identifies protruding loads early, alerts the driver, and automatically reduces speed.
Challenges in narrow aisles
Multidirectional sideloaders are frequently utilised in narrow-aisle warehouses. To maximise storage capacity, these vehicles operate within guidance systems with very limited safety clearance, often with less than 100 millimetres on each side. This increases space efficiency but restricts the driver’s visibility. It becomes particularly critical when long items are stored at an angle or when neighbouring loads are inadvertently moved during retrieval. Parts may protrude into the aisle and aren’t always visible in time from the cabin, especially on the engine side. This can lead to contact issues and costly damage to the chassis, battery, cabin or rack system. In the timber, metal and general industrial trade, with hundreds of moves per day, this scenario is commonplace.
Monitoring with laser-based sensors
The system utilises Lidar sensors to assess vertical planes in the vehicle’s environment. Sensors are mounted at suitable positions based on vehicle configuration and scan both forwards and in reverse. This ensures early detection of protruding loads, whether the forklift enters the aisle forwards or backwards. The monitored area dynamically adjusts to key parameters, with speed, lift height and configuration determining the size of the protective zones. This allows for precise, needs-based detection of potential collision zones without burdening the driver with additional tasks.
The Clear Aisle Assist does not replace personal protection technology but supplements it with collision protection for loads protruding from the rack system. If the system detects an obstacle, it issues a warning first. If necessary, the system automatically reduces speed to avoid contact or minimise its consequences. The goal is an assistance system that effectively enhances the driver’s focus and maintains material flow in tight layouts.
“Our aim was to develop an assistance system that actively supports the driver without adding extra burden”, states Michael Röbig, Head of Product Management at HUBTEX. “The Clear Aisle Assist recognises dangerous situations early and can, if needed, not only warn but also automatically reduce the vehicle’s speed.”
The system is now available for the PHOENIX series and complements existing personnel protection scanners by providing protection against goods protruding into the aisle.
