app l i c at i o n i n f o r mat i o n

Solutions for Very Narrow Aisle Vehicles Aisle Alert System™

Aisle Alert System for Improved Warehouse Efficiency Increase Productivity and Safety Every year there are many avoidable injuries and accidents in warehouses and distribution centers involving very narrow aisle (VNA) trucks. Equipping the VNA machines with the Aisle Alert System can help minimize those accidents and subsequent lost productivity, investigations, and litigation. The Aisle Alert System is composed of two main components: non-contact, safety-rated Laser Bumpers™ and an evaluation unit. Mounted on the vehicle, the Safety Laser Bumpers use innovative laser technology to detect in-aisle objects or traffic. Using time-of-flight measurement, the distance to the detected object can be calculated by measuring the time difference between the emission of a laser light impulse and the return receipt of the light impulse that is reflected off the object. If the data show the presence of a person or avoidable object in the truck’s path, the truck is safely decelerated, controlled to a crawl and, if required, stopped prior to a collision (Figure 1).

Detection System

Figure 1

Benefits of the Aisle Alert System Improved safety: wider sensing field enables earlier detection of in-aisle objects or traffic Non-contact solution reduces downtime caused by injuries and accidents Vehicle system slowdown or controlled braking if object or person is detected Higher productivity than using mechanical bumpers Promotes the use of very narrow aisles in warehouses, which lowers facility cost per unit of goods Satisfies safety regulations for safe operation of VNA trucks (Category 2; optional Category 3 – EN954-1, IEC 61508; also OSHA as regulated by 29 CFR 1910.178 (1993))

Service and Support

Installation SICK and ELOKON have been working with many global manufacturers of industrial VNA trucks to make the Aisle Alert System available as an integrated option on new equipment. To serve aftermarket needs for the Aisle Alert System, the package can be retrofitted on all types of VNA trucks. SICK provides installation, startup, and commissioning services for the Aisle Alert System by trained and certified technicians for North American customers.

Maintenance In North America, certified SICK technicians are available to provide routine inspection and maintenance of Aisle Alert Systems. Annual maintenance agreements ensure VNA trucks operate according to the requirements of workplace safety regulatory authorities. SICK can therefore offer equipment, installation, service and support from a single source, ensuring the best possible benefit for the customer.

A global player in sensor, safety and automatic identification technology SICK has 60 years of expertise in automation technology and employs more than 4,000 people in more than 20 countries. SICK is one of the leading sensor, safety system and automatic identification solution providers in the world today. We are not only a component supplier, but also an experienced system partner for large projects in almost all branches of industry. In collaboration with customers, SICK works continually on innovative product ideas and new, future-oriented equipment technologies.

Non-contact, Automated Safety System for Very Narrow Aisle Vehicles The Aisle Alert System is an automated safety system. It helps protect pedestrians when 2 0 wide). W TA 2 4 OD M Anarrow X DT 2 1 0 than 7DTfeet industrial trucks are utilized in very aisles (aislesDTless

Meets Safety Standards The Aisle Alert System meets the North American safety standards and EU Machinery Directives. The Aisle Alert System is safety certified per the requirements of Annex IV of the Machinery Directive 98/37/EG; it also meets OSHA guidelines, as regulated by 29 CFR 1910.178 (1993) and Canadian CCOHS by reference. The National Institute of Occupational Safety and Health advises to limit simultaneous pedestrian and fork truck traffic so as to minimize risk of personnel injury, but this arrangement isn’t always possible in warehouses and distribution centers. As very narrow aisles are not of “sufficient width,” special consideration is required to minimize the risk of accidents between pedestrians and trucks. The use of the Aisle Alert System is an accepted, appropriate way to help ensure safety and fulfills the requirements of providing a safe workplace. The Aisle Alert System meets all the requirements of the OSHA, CCOHS, ANSI, European Safety Directives and other worldwide standards.

System Operations The Aisle Alert System uses innovative laser technology to monitor the cruising range within the narrow aisle. When the Aisle Alert System detects in-aisle objects or traffic, a visual and/or audible warning is triggered, and the truck is automatically decelerated and, if necessary, stopped prior to a collision with the object. Outside the narrow aisle, the Aisle Alert System is in a deactivated state (see Figure 2). The identification of persons or objects does not occur. When a VNA truck enters an aisle, the Aisle Alert System is automatically activated. While the VNA truck travels within the aisle, the hazardous area is monitored in the vehicle’s direction of movement (see Figure 3). When the truck is in the aisle but not moving, the Aisle Alert System is activated in both directions to detect persons and objects approaching the VNA truck. If the Aisle Alert System identifies a person or object in the aisle, the maximum speed of the VNA truck is first reduced to Crawl Speed (1.5 mph/2.5 km/h) (see Figure 4). If the object remains in the vehicle's path, the vehicle automatically decelerates and comes to a stop to prevent collisions (see Figure 5). Once the driver ensures that the truck’s path is clear, the control button resets the alarm and the VNA truck can continue at normal speed.

Figure 2

Figure 3

Figure 4

Figure 5

Product Overview

Standard System Components In the standard configuration, the Aisle Alert System consists of the following components: • Evaluation electronics (normally integrated in the truck’s engine compartment) • A safety laser scanner on the load side (see Figure 6) • A safety laser scanner on the drive side (see Figure 7) • A visual indication and operation module (see Figure 8 – example of an integrated module)

Figure 6

Figure 7

Optional System Components Several optional modules for customized performance and improved productivity are available: • External indication and operation box • Aisle entry and exit detection • Point of stop detection • Recognition of driving direction and speed • Cabin position detection • Wireless transmission and control of the driving function in the cabin

Figure 8

Technical Data

Aisle Alert System Operating temperature

0 ... 50° C

Safety Category

Category 2, optional Category 3 (EN 954-1, IEC 61508)

Aisle Alert Detection

S3000 Safety Laser Scanner

Resolution

≥ 70 mm

Laser classification

1

Minimum reflectance

≥ 1.8% diffuse

Range of safe detection

≤ 7.0 m

Range of warning field

≤ 49 m

Hardware Options Load Identification

Fixed Bar Code Scanners: CLV450, CLV490; Handheld Bar Code Scanner: IT Series

Overhang Clearance Alert

Laser Scanners: LD, LMS, S300, S3000

Fork Height Min-Max Detection

Photoelectric Sensors: W260, DT2; Safety Position Switches: i110R, i110P

Fork Height Measurement (continuous)

Distance Measurement Sensors: DL60, DT60, DT500; Wire Draw Encoders: BTF13

Collision Avoidance/Alert

Laser Scanners: LMS, S3000

Driver-in-Seat Protection

Photoelectric Sensors: W9, W18, W280, W12, W24; Ultrasonic Sensors: UM30

Mast Angle/Tilt

Distance Measurement Sensors: DT2, DT20, WTA24

Operator Containment (in vehicle)

Photoelectric Sensors: WS/WE 45; WS/WE 12L, ELF; Light Grid: PLG; Safety Sensors: L400

Overhang Detection (of product in aisle)

Laser Scanners: LMS, S3000; Light Grids: ELG, MLG

Load Detection

Photoelectric Sensors: W9, W18; Ultrasonic Sensors: UM30

Vehicle-to-Load Positioning

Photoelectric Sensors: W24; Distance Measurement Sensors: DT60

Internal Mechanical Positioning/Monitoring

Inductive Sensors: IM, INOX; Safety Position Switch: i110R

Vehicle Speed Monitoring

Encoders: ARS60, DKV

kh 5 3

Additional Capabilities

Features The mode of operation and the technical characteristics of the basic control module can be extended at the request of the customer by using additional modules. Either for greater functionality and results or for simpler and more comfortable operation, the following are either included with the system or are additional options available: Included: • Crawl Speed for Obscured Laser Scanner (KR) When the forks are completely lowered, the truck’s speed is automatically reduced to crawl speed to minimize risk of contact with people or other objects in the vehicle’s path. The manual deactivation of the Aisle Alert System is not required (See also Figure 9). • "Smart" Detection (KAD) The Aisle Alert System is programmed so that neither crossing traffic nor stationary objects, such as walls, that are located in the direct path of a fork truck will lead to false alarms (See also Figures 10 and 11). Options: • End of Aisle Safety (GES) The speed of the VNA truck is automatically reduced to a crawl speed of 1.5 mph/2.5 km/h when leaving the aisle and when crossing aisles. • Mixed Operation (MIXED) The Aisle Alert System allows for the alternate and simultaneous presence of persons and a VNA truck in a very narrow aisle. For this application, special considerations must be taken in order to minimize the risk of accidents.

WALL

Figure 9

Figure 10

Figure 11

R A N G E OF E x p e r t is e

S a f e t y S y s t e ms

A u t o mat i c I d e n t i f i c at i o n

A n a ly z e r s a n d P r o c e ss I n s t r u m e n tat i o n

SICK is one of the world’s leading manufacturers of sensors, safety systems, and automatic identification products for industrial applications. SICK holds more than 450 patents for its innovative products. Through its Industrial Sensors, Safety Systems, Automatic Identification, and Environmental and Process Analysis divisions, the company has operations in 65 countries. SICK North America is headquartered in Minneapolis, MN.

Products from SICK provide comprehensive safeguarding of both workers and machinery. As experts in sensor technology, SICK develops and manufactures pioneering products that provide protection in hazardous zones, dangerous locations and for safeguarding access points. By providing services, which encompass all aspects of machine safety and security, SICK is setting new standards in safety technology.

Our wide range of sensors provides solutions to suit any application in the field of automation. Even under rugged ambient conditions, objects are reliably detected, counted and positioned regardless of their form, location and surface finish.

Whether the tasks involve identification, handling, classification or volume measurement, innovative automatic identification systems and laser measurement systems from SICK function reliably, even under rapid cycle times. Products from SICK conform to the latest standards and can be easily integrated in all industrial environments and external applications.

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