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1 Forklift based warehousing
Due to its cheap price and strong loading capacity, forklifts have been widely used in factories, which greatly improves the flow
efficiency of warehouse materials. However, in the use of forklifts, there are also some risks, and even some accidents. On the
other hand, how to effectively digitize the warehouse and improve the operational efficiency of the warehouse is also a part of
the digitization of the warehouse in intelligent manufacturing.
1.1 Security
Forklift is a special vehicle, due to the driver's training is not in place, or in the driving, due to the large visual blind area, speeding,
overloading and other reasons, resulting in frequent accidents.
1.2 Personnel safety accidents caused by forklifts
Forklift accidents in Zhejiang Province in recent five years
According to statistics, from 2017 to the end of 2021, a total of 27 forklift accidents occurred in the province, killing 26 people and
injuring 1 person, and the relevant classification analysis is shown in Figure 1-Figure 4. The details are as follows:
In 2017, there were 5 forklift accidents in the province, accounting for 50% of the total number of special equipment accidents in
the year; Five people died, accounting for 50% of the total number of deaths in special equipment accidents that year.
In 2018, 7 forklift accidents occurred in the province, accounting for 70% of the total number of special equipment accidents in the
year; Seven people died, accounting for 70% of the total number of deaths in special equipment accidents that year.
In 2019, there were 5 forklift accidents in the province, accounting for 55.6% of the total number of special equipment accidents in
the year; Five people died, accounting for 55.6% of the total number of deaths in special equipment accidents that year.
In 2020, there were 4 forklift accidents in the province, accounting for 44.4% of the total number of special equipment accidents in
the year; Four people died, accounting for 50% of the total number of deaths in special equipment accidents that year.
In 2021, 6 forklift accidents occurred in the province, accounting for 85.7% of the total number of special equipment accidents in the
year; Five people died, accounting for 83.3% of the total number of deaths in special equipment accidents that year.
Through sorting out the statistics of 27 forklift accidents in the province, it is found that the accidents mainly occur in the use of the
link, the direct cause of the accident is illegal operation, and there are a variety of illegal behaviors in each accident.
By the end of 2021, 195,000 forklifts had been registered in Zhejiang Province, accounting for 11.9% of the province's total special
equipment, about 12.5% of the country's total forklifts, and maintaining a higher growth rate of more than 10% every year.
According to the corresponding proportion, there are nearly 1.6 million forklifts in use throughout the year, and if the proportion of
accidents is calculated, there are more than 60 people a year because of forklift accidents.
The data from Toyota also shows that.
Not only at home, in foreign countries and even some developed countries, but also forklift accidents occur frequently.
Singapore
2022/7/9 29th fatal work accident this year【link】
UK
With some 1,300 UK employees hospitalised each year with serious injuries following forklift accidents*, key contributing factors
can be lapses in driver concentration, or increased speed and
Excerpts from Sick's documentation【link】。
Germany
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.
Excerpts from Bosch's documentation【link】。
1.3 Some common accident categories
1, goods block the driver's line of sight
Case 1: Forklift cargo blocked the driver's line of sight, failed to find the front of the person, resulting in a rolling accident.
Case 2: When a forklift truck is driving, its sight is blocked by the goods, knocking down the people in front of it.
2, workers use the body as a counterweight
Case 3: In order to maintain the balance of the forklift when lifting heavy goods, the staff used the weight as the counterweight,
which almost caused casualties.
Case 4: After an employee used his weight as a counterweight imbalance, other employees came to help and were overwhelmed
by a forklift.
3. The goods are too wide or unstable
Case 5: The width of the forklift cargo exceeds the allowable width of the route, and it is hung on the roadside shelf, which almost
causes an accident.
4. Speeding
Case 6: A forklift truck was speeding and overturned during a turn.
Case 7: The forklift truck was speeding, overturned, the driver was not wearing a seat belt, jumped out and was crushed.
5, forklift driver illegal driving
Case 8: The forklift driver did not notice the pedestrian, and the pedestrian did not notice the forklift.
Case 9: The forklift truck did not observe the rear situation when reversing and hit the rear pedestrian.
6, forklift illegal transport personnel
Case 10: forklift illegal lifting personnel, forklift driver did not wear a safety belt, forklift lifting personnel fell and the driver was crushed
during rollover.
Case 11: When the forklift truck is transporting goods, the worker stands on the goods, and the personnel also falls at any time when
the goods are dumped.
7. The forklift driver is not wearing a seat belt
Case 12: The driver of a forklift truck was not wearing a seat belt and was crushed when he fell off the truck.
2 Solution
Forklift anti-collision warning system adopts high-precision UWB ranging technology, the vehicle is installed with anti-collision host
and sound and light alarm, and the personnel wear anti-collision labels. When the forklift checks the person or the forklift checks the
forklift, the alarm will sound, and the alarm sounds are different at different distances. You can also set an area to limit the speed
within the area. The installation of forklift anti-collision system has improved the problem of safe operation in the forklift factory.
(1) forklift and human collision prevention: the vehicle is installed with the anti-collision host, and the sound and light alarm, the
personnel wear the anti-collision label, and the sound and light alarm when the distance between the workshop is too close.
(2) forklift and forklift anti-collision: all vehicles install anti-collision host, and sound and light alarm, when the distance between vehicles
is too close, the sound and light alarm on the vehicle.
Because the forklift ranging anti-collision alarm system can achieve early prevention alarm, it can avoid emergency braking, save vehicle
wear and tear, and reduce the risk of accidents to maintain good operational efficiency. If the throttle controller is optional at the same
time, when the distance between people and vehicles is too close, the system can make the forklift automatically slow down and stop,
truly ensure safety.
2.1 No network Deployment
The ability to detect each other is achieved by equipping the working vehicle and operator with UWB tags. Without the need for basic
network deployment, it dynamically senses the relative position of moving objects, triggers an audible and visual alarm according to
the preset safety distance threshold, and prompts to take precautionary measures. The scheme has the characteristics of low cost
and rapid deployment.
• No network deployment is required, and the collision avoidance detection delay is less than 0.1 seconds
• Original information architecture, eliminate interaction delay bottleneck, improve the stability of the system
• Integrated anti-interference mechanism to significantly reduce background noise, system capacity up to 100 tags /400 square meters
2.2 Network Deployment is available
Through the real-time positioning of forklift trucks and personnel with centimeter-level accuracy, the information is timely feedback to
the business control system, which realizes the functions of vehicle and personnel safety control, collision avoidance, access control,
vehicle personnel dynamic scheduling, and motion trajectory backtracking, etc., meeting the needs of customers for accurate positions.
• Real-time location network perfectly supports collision avoidance alarm delay requirements
• Electronic fence alarm delay does not exceed 0.02 seconds
• Downlink TDoA enables the tag to have edge computing and judgment capabilities
3 case
3.1 Shengmu Dairy vehicle collision prevention project
Bayannur Shengmu Dairy factory forklift safety management, to prevent forklift and personnel collision, strengthen safety production,
reduce the accident rate.
According to the demand, set 4 meters, 6 meters secondary alarm distance. Through the PWS system, the dangerous distance alarm
between forklift and forklift and between forklift and human is realized.
3.2 Sinopec Forklift operation safety management project
Provide Sinopec with real-time positioning of forklift trucks, real-time monitoring of personnel, real-time display of all personnel in the
area, dynamic grasp of the number and distribution of personnel, set up electronic fences, enter the restricted area or unsafe area alarm.
To collect and analyze abnormal behavior data, build big data model.
It solves the problems such as large working area of forklift truck, less personnel, difficult scheduling, abnormal dangerous goods can
not be reported in real time, and specific area management.
