Pedestrian Avoidance System for Industrial Safety

Problem Statement


Collision risks: One of the main problems in forklift safety is the risk of collisions between forklifts and other vehicles, as well as between forklifts and pedestrians. This can cause injuries and damage to equipment.


Blind spots: Forklifts have blind spots, which can make it difficult for operators to see other vehicles and pedestrians. This increases the risk of collisions.


Fatigue: Operating a forklift for long periods of time can lead to operator fatigue, which can result in decreased reaction times and increased risk of accidents.


Poorly maintained equipment:Forklifts that are not properly maintained can be more prone to accidents and breakdowns, which can create hazards for operators and other employees.


Limited visibility: Forklifts often operate in poorly lit or crowded warehouses, which can limit visibility and increase the risk of collisions and accidents..

Solution Overview


One of Australia's providers of vehicular interaction solutions approached OptiSol to develop a Pedestrian Avoidance System (PAS) in order to protect the staff and operators of forklifts from potential harm.


Their traditional collision avoidance systems create high numbers of nuisance alerts, which leads to drivers ignoring alerts, which dilutes the value of the system.


OptiSol designed a solution that uses Deep Learning to identify humans and calculates their risk in the proximity of forklifts.


We used AI/ML to minimize false alarms by evaluating multiple danger factors around the vehicles through various AI/ML algorithms.


Our designers also added enterprise features and management capabilities to the solution, notifying managers of incidents that would have gone unreported.

Business Impact


Improved safety: AI-based pedestrian avoidance systems can help reduce the risk of collisions between forklifts and pedestrians, which can lead to fewer accidents, injuries and fatalities.


Real-time monitoring: AI can provide real-time monitoring of the warehouse environment, which can help to detect potential hazards and alert operators to take action.


Increased Efficiency: AI can help operators navigate through the warehouse more efficiently, reducing the risk of collisions and improving overall productivity.


Cost savings: AI-based systems can help businesses save money by reducing the number of accidents and associated costs, such as lost time, legal fees, and insurance claims.


Compliance: AI-based systems can help businesses comply with safety regulations, which can help avoid penalties and legal issues.

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OptiSol’s Approach

The PAS devices on the forklifts are connected to the Cloud through IoT Core, which helps manage each device and facilitates data exchange with each device. The whole PAS solution comprises of various AWS services that receive and processes data from the device and provides data and instructions to each device.
The device sends telemetry, state and event data to AWS where the data is scrutinised and decisions are made. Data is also used for reporting and analytics for managers that operate forklifts through the enterprise portal. Managers are prompted with events that are regarded as significant. Images relating to significant events are available for download.

Goal Achieved

Each vehicle has an IoT device and camera(s) installed. This IoT device communicates to AWS IoT Core using MQTT messages. The AWS architecture performs various tasks such as management of each IoT device, upload of images and videos as well as telemetry data. Each device contains accelerometers, temperature, humidity, and many other sensors. This data is fed to the Cloud where AI/ML algorithms derive insights. For example, we can determine if an event has taken place that managers might think of as significant. If so, we send the appropriate manager a message. We can also estimate the maintenance requirements of each vehicle based on the time in use and how hard the vehicle is being used. Managers can access detailed reports that combine all information, including images. For example, managers can download accident or incident information (including images) that can be used in investigations by safety officers or authorities.

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