A mixed fleet approach is appealing as it allows human workers to focus on more complex and value-added activities while AGVs handle repetitive and labour-intensive tasks, increasing productivity and operational flexibility. Nevertheless, if safety is a significant concern in any warehouse, those utilising AGV solutions are no exception. As we move towards collaborative environments where AGVs and manual operations coexist and collaborate with one another, new safety considerations emerge. 

Safety protocols must be followed by everyone involved. AGVs should be equipped with advanced sensors and collision avoidance systems to ensure safe operations around human workers and other equipment. On the other hand, manual operators and pedestrians need to be trained to understand the paths and operations of AGVs. For instance, they should follow designated walkways, adhere to signage, and pay attention to AGV signals to reduce human error and ensure smooth operations. 

ISO 3691-4 is an international safety standard that specifies the safety requirements and verification methods for driverless industrial trucks – such as AGVs and AMRs – their systems, and the means to ensure their safety. This standard ensures that these vehicles operate safely in environments where they interact with human workers and other equipment.

Safety measures in AGV technology 

At Rocla AGV Solutions, we prioritise safety by incorporating a comprehensive set of safety functionalities in our vehicles and ensuring compliance with the ISO 3691-4 safety standard. This means our vehicles come equipped with essential safety features, such as safety scanners and a safety logic controller that monitors speed and lifting height and even residual load in some cases. “ISO standardisation is vital, and naturally, we have issued the CE mark to our AGVs as well. Rocla AGVs are designed with safety in mind, and all our operations have been built to achieve the standard and enhance collaboration between AGVs and manual operators”, comments Matti Rintala, Solution Architect, Solutions Management at Mitsubishi Logisnext Europe. For example, the number of safety scanners has increased, but that’s not all. Enhanced area surveillance and the increased number of detection field sets have significantly changed the modern AGVs,” adds Kari Johansson, Vice President Solutions Management at Mitsubishi Logisnext Europe. 

For specific requirements, we also offer additional safety measures, such as the Proximity Detection System (PDS), which facilitates smooth collaboration between manual operations and AGVs in shared spaces. 

Our advanced navigation systems, sensor technologies, and collision avoidance systems enable AGVs to adapt to sudden changes in layouts and tasks, ensuring safe interactions between AGVs and human workers and reducing the risk of collisions. “The ISO-3691-4 standard requires more from the safety fields, as the need to cover all directions of movement, including the direction the vehicle is turning. Side monitoring is related to the standard’s requirement that the vehicle must reduce its speed when the detected space on the side is less than 0.5 m. In addition, it also requires that in certain situations, and in the absence of lateral space, the vehicle must not restart automatically after a stop caused by the safety field, even if the safety field stopped detecting the target”, adds Rintala. 

By interpreting the standard very strictly, we are able to integrate AGV solutions into existing environments with unusual layouts, uneven loads, low-visibility areas or mixed traffic without needing to isolate the vehicles or restrict the areas.  

In addition to adhering to current regulations, regular maintenance audits are essential to ensure that the vehicles are functional and continue to meet the original requirements. By adopting a proactive approach, businesses can identify and address potential failures in the AGV system before they escalate into major issues. Prompt responses to potential threats can also prevent costly repairs and replacements. 

At Rocla AGV Solutions, we count on comprehensive service packages that answer each customer’s needs. Selecting the right package is essential for ensuring the longevity of the AGV fleet and that the solution continues to contribute to smoother operations and high productivity, with AGVs operating safely, reliably, and efficiently. For instance, our Full-service package includes maintenance audit, preventive maintenance, software maintenance, email support, 24/7 AGV Helpdesk support and spare parts and work on unexpected failure. 

Watch the video below to discover how Avant Tecno, a leading manufacturer of multifunctional compact loaders, leverages the Full-service package to maximise the longevity and lifespan of their AGV solution and enjoy the peace of mind that comes from knowing their environment remains safe and reliable for years to come. 

Safety measures for manual operations  

Manual operations may involve human error, which can lead to unsafe interactions with AGVs. Training and clear protocols are essential to minimise these risks. Therefore, effective facility management is crucial for creating a harmonious and productive environment where both AGVs and human workers can thrive. 

The facility must implement and enforce comprehensive safety protocols including clear signage, designated pathways, regular safety audits of the facilities and available equipment, and ensure that both AGVs and manual operators follow the established safety guidelines. 

The importance of traffic management 

The presence of both AGVs and manual equipment like forklifts can create unpredictable traffic patterns, complicating the maintenance of a safe environment. In mixed traffic settings, effective traffic management systems are essential to ensure safety by boosting coordination and communication between the involved parties. 

Our in-house-developed FleetController software allows you to monitor and manage your entire fleet from one place. FleetController not only integrates with the existing WMS (Warehouse Management System) and keeps the fleet running automatically, but it can also plan the order of task execution according to the deadlines given by the WMS. 

To stay on schedule, FleetController can automatically and actively manage the task allocation between AGVs and forklifts, and with the AMFC (Automated Material Flow Control) in place, FleetController can react to sudden changes and errors during operations, conveniently reallocating tasks to AGVs or driver-operated forklifts indistinctively. 

The intuitive and user-friendly FLO app serves as a platform for forklift drivers to receive tasks from FleetController. 

Key takeaways to collaborate safely 

By adhering to ISO 3691-4, we ensure our AGVs meet the essential health and safety requirements set by the EU Machinery Directive, providing more reliable and uninterrupted AGV operations also in environments with pedestrians and driver-operated forklifts. Rocla AGVs operate safely in shared environments, interact with humans and enable mixed fleet operations, enhancing the overall productivity of our customers’ warehouses. Additionally, we emphasise the importance of training all other involved parties to understand AGV paths and operations, follow designated walkways, and adhere to safety signage to create a safer and more efficient working environment. “Nothing is more important than safety, and ensuring safety without compromising efficiency is vital” concludes Johansson.