Still GmbH, part of the KION Group, has launched the "Active-Guard" safety system as standard equipment on its RX 60-25 series 2.5-ton electric counterbalance forklifts, targeting the persistent challenges of pedestrian-struck incidents and unauthorized forklift operation in shared warehouse and logistics environments. Traditional forklifts rely entirely on the operator to maintain visual awareness of pedestrians and on simple seat-switch interlocks to prevent unauthorized starting. Both approaches have known gaps: pedestrians frequently walk behind racking and out of the operator's sightline, and seat switches can be defeated with simple seat pressure tricks or bypassed entirely.
The Active-Guard system integrates two complementary sensing modalities. First, a "Capacitive Seat-Occupancy Array" embedded within the operator's seat cushion senses the operator's body mass distribution and posture. Unlike a simple pressure switch, the capacitive array detects the operator's actual presence, posture, and whether the operator is seated correctly with both hands on the steering wheel (via paired capacitive touch zones in the steering wheel). If the operator leaves the seat with the travel pedal depressed, the system cuts the traction circuit within 200 milliseconds-preventing "dead-man runaways" that previously occurred when an operator slid forward off the seat with their foot still on the accelerator.
Second, the system fuses a "77-GHz Automotive-Radar Array" mounted at the truck's counterweight, providing a 180-degree forward view with a 15-meter detection range and a 5-meter rear-view radar. The radar's point-cloud data is processed by an onboard AI classifier that distinguishes human silhouettes from stationary racking, pallets, and other trucks. When a pedestrian enters the truck's forward path at any distance, the system activates a "Progressive Warning Stage"-first illuminating a blue "Pedestrian Detected" spot light ahead of the truck to alert the pedestrian, then issuing an in-cab visual and audible warning to the operator. If the pedestrian continues into the 2-meter emergency zone, the system automatically engages regenerative braking and ultimately applies the friction brake, bringing the truck to a complete stop without operator intervention. The system logs every detection event, providing warehouse safety managers with data on near-miss locations, allowing proactive layout improvements. This multi-modal safety approach reduces pedestrian-struck incidents by 90 percent and blocks unauthorized use in shared warehouse environments.
