As the “core hub” of the modern supply chain, logistics and warehousing operations run at high speed every day. Storage, material handling, sorting, and distribution are closely interconnected and directly determine the efficiency and continuity of the supply chain.

However, behind this high efficiency lie numerous hidden safety hazards: AGV collisions at corners, sudden crushing by lifts, forklift collisions caused by blind spots, and entanglement with conveyor machinery. These hazards not only threaten workers' safety but may also result in operational downtime and property damage.

Today, we will examine the specific safety challenges associated with four major types of warehouse equipment and introduce a comprehensive “active warning + passive protection” approach to build a stronger warehouse safety system.

1. AGVs: Worried About Collisions During Smart Material Handling? Dual Protection for Millisecond-Level Risk Prevention

AGVs are the workhorses of automated warehouse transportation. However, in busy pedestrian aisles, equipment intersections, or around corners with stored goods, they may fail to identify obstacles in time, resulting in collisions or run-over accidents.

Advanced Protection Solution: “Smart Eyes + Soft Safety Edge” Double Protection

① LiDAR: Multi-Level Warning for Early Risk Prevention

Install LiDAR sensors at the front and rear of the AGV as its “smart eyes”, with three configurable protection zones:

Warning zone: When an obstacle enters the warning zone, an alarm light is activated.

Deceleration zone: When the obstacle enters the deceleration zone, the AGV automatically reduces its speed.

Stop zone: When an obstacle enters the stop zone, the AGV stops immediately.

This creates a complete protection loop from early warning to automatic braking.

② Safety Edge: Stop on Contact and Protect the Final Safety Barrier

Install a highly sensitive “soft anti-collision edge” along the AGV. If the edge comes into contact with a person, cargo, or equipment, it immediately interrupts the operating command, helping prevent severe hard-impact collisions.

2. Lifts: Worried About People Being Trapped or Crushed? 270° Scanning + Soft Safety Edge for Dual Protection

Lifts are essential for transporting goods between floors. However, accidents can occur when people remain near the entrance or when goods have not been completely moved out before the lift doors close and the lift begins to descend.

Advanced Protection Solution: “Active Lockout + Passive Shutdown” for Comprehensive Protection

① LiDAR: 270° Scanning to Block Hazardous Commands

Install a LiDAR sensor above the lift entrance to create an editable 270° fan-shaped detection zone.

Whether a person remains at the entrance or cargo has not completely cleared the doorway, the system can block the door-closing or downward-movement command, helping prevent hazards before they occur.

② Safety Edge: Stop Immediately Upon Compression

Install a Safety Edge along the edge of the lift door. This highly sensitive passive protection device immediately stops the door movement when it contacts a person or object, helping prevent crushing injuries at the source.

3. Forklifts: Worried About Blind-Spot Collisions? Two-Way Warning + Emergency Braking

Forklifts are essential for heavy-duty material handling in warehouses. However, they often operate in crowded areas and narrow aisles, while the driver's field of vision may contain significant blind spots. As a result, nearby personnel may go unnoticed, increasing the risk of collisions.

Advanced Protection Solution: “Two-Way Person-Vehicle Warning + Instant Shutdown”

① Active Warning: Two-Way Alerts Between Forklifts and Personnel

Install a dedicated forklift anti-collision positioning sensor, such as the Moncee Minyou MMP-PBS.

A safety sensor is installed on the forklift, while workers wear positioning wristbands. When a worker enters the predefined warning zone, an audible and visual alarm is immediately triggered.

This simultaneously alerts the forklift operator that “a person is nearby” and warns the worker to “move away from the forklift.”

② Passive Braking: Safety Edge as the Final Protection Layer

Install a Safety Edge around the forklift. If a collision occurs and physical contact is detected, the forklift can immediately stop, helping prevent the injury from escalating.

4. Conveyor Lines: Worried About Entanglement During High-Speed Sorting? Three Protection Options for Different Applications

Conveyor lines are the core arteries of warehouse sorting and transportation systems. High-speed conveyors and gaps between machines can create risks of mechanical entanglement and crushing, particularly during manual sorting, maintenance, or inspection when personnel may accidentally enter hazardous areas.

Advanced Protection Solution: Choose One or Combine Multiple Devices

① Safety Light Curtain: Invisible Safety Barrier for Immediate Shutdown

Install a Safety Light Curtain at entrances and exits of hazardous areas to create an infrared protective barrier.

Whether a person or an object interrupts the light curtain, the equipment immediately stops. The system provides rapid protection without interfering with normal operations.

② Safety Mat: Step-Activated Protection for Frequent Crossing Areas

Install Safety Mats along pedestrian passageways where workers frequently cross.

If someone accidentally steps into the protected area, the pressure-sensitive mat immediately triggers equipment shutdown. This is particularly suitable for applications where personnel frequently need to cross conveyor lines.

③ LiDAR: Customizable Protection for Complex Layouts

LiDAR can be installed at key points around the conveyor line, with the shape and size of the protection zone freely configured.

Whether the production layout is complex or the hazardous area has an irregular shape, LiDAR can detect personnel or obstacles entering the predefined protection zone.

Overview of Core Safety Protection Devices

√ LiDAR: Advanced Active Protection

Intelligent scanning and customizable protection zones make LiDAR suitable for complex applications such as AGVs, lifts, and conveyor systems, allowing potential hazards to be detected in advance.

√ Safety Edge: Reliable Passive Protection

With high sensitivity and convenient installation, Safety Edges provide AGVs, forklifts, and lifts with a soft anti-collision layer that can trigger an immediate stop upon contact.

√ Safety Light Curtain / Safety Mat: Dedicated Conveyor Protection

Suitable for different operating environments, these solutions provide rapid response without unnecessarily affecting productivity, helping prevent mechanical entanglement and crushing injuries.

√ Dedicated Forklift Anti-Collision Sensor — Moncee Minyou MMP-PBS

Designed specifically to address forklift collision risks, the system provides two-way warning between personnel and vehicles, offering a more comprehensive solution than relying on a single protection method.

Let's Talk About Warehouse Safety

▲ What safety challenges does your warehouse currently face? AGV path conflicts, forklift blind spots, or conveyor-line hazards? Feel free to send us your inquiry.

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