AI and modern sensor technology: How do they increase safety in the warehouse?

AI (artificial intelligence) and sensors are already part and parcel of our everyday lives. They are found in many scenarios, including facial recognition on our smartphones, personalized movie recommendations on streaming platforms, and autonomous vacuum-cleaning robots. The systems are also already firmly established in intralogistics – for example, by minimizing the dangers of working with forklift trucks.

In its 2019 study, Germany’s statutory work accident insurance organization (DGUV)* recorded an average of 144 accidents with industrial trucks every working day. The most common causes were restricted operator visibility, a lack of experience, and lower attentiveness during straining shifts. And it is in these situations that sensors and AI can help.

Intelligent assistance systems help prevent collisions and tipping

Linde Material Handling has developed a number of systems capable of compensating for operator error. One example is the Linde Rack Protection Sensor for reach trucks. When putting away or retrieving goods the truck driver needs to focus fully on the loaded pallet. Although their field of view is typically obstructed, they have to work with precision to avoid collisions and damage on supporting rack columns or the goods. A sensor can accurately measure distances and automatically initiate braking if the truck is approaching an obstacle too quickly. As a result, the operator can concentrate entirely on their load.

A less frequent but potentially far more dangerous incident compared to damage during racking operations is an overturned forklift truck. In these circumstances, the Linde Safety Pilot (LSP) provides a solution. This assistance system is based on multiple integrated sensors. These measure factors such as fork lift height and load weight. A cab display provides the operator with all key information at a glance. When there is a risk of the vehicle tipping, the LSP system issues both acoustic and visual alarms – and the Active Version even intervenes automatically.

Safe interaction between people and machines

However, powerful sensors not only ensure safety in their own right, they also form the basis for the use of artificial intelligence. Thanks to them, large amounts of data can be processed and analyzed, which in turn enables unique insights and intelligent predictions. Intralogistics expert STILL has also developed a variety of pioneering products designed to mitigate dangers in warehouses. Dynamic Load Control is a further means of minimizing the risk of a truck tipping over. And the iGo neo range from STILL raises safety during picking operations to a whole new level. Operators of picking devices have to pay attention to multiple things simultaneously, increasing the likelihood of human error and accidents. The OPX iGo neo addresses this issue. This autonomous, self-navigating picking truck features a multi-stage safety concept that protects people, warehouse infrastructure and goods. Special sensors recognize both dynamic and static warehouse objects. The OPX iGo neo takes its lead from the operator, following them as they walk, and stopping at the ideal picking position. Artificial intelligence adjusts vehicle movements and speed to the specific task.

It maintains safe distances at all times, and comes to a halt whenever there is an obstacle in its way.

These and many other examples demonstrate that AI and sensors are now essential elements of modern warehouse environments. As automation advances, its importance will continue to increase. This will sustainably raise not only the safety but also the performance of intralogistics processes.


*German only