Anti-Collision and Safety Protection Technologies for Automated AS/RS

The anti-collision and safety protection of an automated AS/RS is a multi-level technical system integrating active early warning, passive buffering, system interlocking, and intelligent monitoring. Centering on key equipment such as stackers, AGVs/AMRs, racks, and conveyors as well as manual operation scenarios, it forms a closed loop of perception–judgment–control–protection to prevent risks including collision, falling, pinching injury, and structural collapse. Adapted to complex scenarios of supermarket distribution centers featuring high-frequency operation, multi-category storage, and mixed pedestrian-vehicle traffic, it balances safety protection and operational efficiency, providing comprehensive guarantee for the stable operation of automated AS/RS.

I. Core Anti-Collision Technologies (Active Collision Avoidance + Passive Buffering)

The core goal is to actively avoid collisions between equipment, between equipment and racks, and between equipment and obstacles, reducing equipment damage, rack deformation and commodity breakage. Widely applied to core automated equipment such as stackers, AGV/AMR robots and conveyors, it builds a full-process anti-collision mechanism of perception, early warning and braking.

(1) Stacker Anti-Collision (Core Protection for High-Rise and High-Speed Operation)

Stackers operate at high speed horizontally and vertically for high-altitude cargo access, making them the key focus of AS/RS anti-collision. Adopting triple protection of multi-sensor fusion, mechanical limit and software interlocking, it adapts to the collaborative operation of multiple stackers in multiple aisles:

1. LiDAR / Laser Ranging Anti-Collision (Non-Contact)Safety laser scanners or LiDAR are installed on the stacker body and forks for 360° or 180° peripheral scanning, dividing three zones: deceleration in the far area, early warning in the middle area, and emergency stop in the near area. It real-time monitors the distance to rack columns, adjacent equipment and obstacles with an error of ±1~2 mm and a response time ≤30~40 ms, automatically decelerating or stopping when below the safety threshold. Combined with real-time path scheduling of the WMS system, cross collisions are avoided.

2. Contact Intelligent Anti-Collision (Dedicated for Forks)Safety edge strips or wireless trigger devices are mounted at the front of forks with a triggering force of only 20~60 N. Upon collision, signals are transmitted to the PLC for emergency shutdown within 30 ms, with the impact distance controlled within 50 mm. Matched with torque limiters, the forks slip automatically when encountering excessive resistance, protecting forks, pallets and racks.

3. Mechanical Limit and Buffering (Final Protection)Mechanical and electronic limit switches are installed at both ends of the track and lifting limits to cut off power and force an immediate stop once overtravel occurs. Hydraulic or rubber buffers are arranged at the track ends to absorb impact energy out of control and protect the equipment structure.

4. Anti-Falling and Over-Speed ProtectionThe loading platform is equipped with speed-limiting and anti-fall devices. In case of steel wire rope or chain breakage and over-speed descending, it mechanically locks the column to prevent the falling of goods or the platform.

(2) AGV/AMR Anti-Collision (Full-Coverage Flexible Shuttle Protection)

AGV/AMR robots conduct flexible transshipment with mixed pedestrian and vehicle flow in the warehouse. Adopting four-level redundant anti-collision design, it adapts to cross-operation scenarios of personnel and equipment:

1. LiDAR Main Protection (360°)Safety laser scanners with a protection range of 0~4 m and 270° scanning dynamically divide deceleration and parking zones, automatically slowing down or stopping when detecting personnel or obstacles, and resuming operation automatically after obstacles are removed.

2. Infrared / Ultrasonic Auxiliary Obstacle AvoidanceCompensating for laser blind spots and unaffected by dust and light, it can detect low and small obstacles to realize precise early warning at close range.

3. Safety Edge (Contact Final Protection)The vehicle body is fully covered with flexible safety edges, which cut off power and stop immediately upon contact with obstacles, requiring manual reset for restarting.

4. Emergency Stop Button + Acoustic and Optical WarningVisible emergency stop buttons are arranged at multiple positions on the vehicle, with acoustic and optical alarms (flashing lights + buzzers) throughout operation to remind surrounding personnel to yield.

(3) Rack Anti-Collision (Basic Structural Safety Protection)

As the core load-bearing structure of automated AS/RS, rack anti-collision focuses on preventing deformation of columns and beams to ensure overall structural stability and comply with relevant industry specifications:

1. Column Anti-Collision Corner / Foot GuardHigh-strength Q460 steel anti-collision corners (thickness ≥10 mm) are installed at vulnerable positions such as ground floors and corners to buffer equipment impact and prevent column deformation. Reflective marks are pasted on the surface to improve recognition during equipment operation.

2. Slot Anti-Drop ProtectionFlexible baffles or metal guard plates are mounted at the edge of storage slots to prevent cargo deviation and protrusion that may cause collisions, keeping goods intact.

3. Rack Structural ReinforcementHigh-rise racks are equipped with horizontal tie rods and diagonal braces to enhance anti-collision stability. Regular inspections are conducted on rack deformation, settlement and loose bolts for timely reinforcement and maintenance.

(4) Conveyor / Sorting Line Anti-Collision

Adapted to continuous commodity conveying scenarios, it mainly prevents commodity congestion, jamming and collision at equipment connections:

1. Speed Synchronization + Congestion DetectionLinked with the operating speed of stackers and AGVs to avoid commodity falling and collision caused by inconsistent speeds. Infrared sensors are installed at conveying nodes to automatically slow down or stop when detecting congestion and jamming, preventing piled collisions.

2. Pinch Point Protection + Protective CoverTransmission parts are fully enclosed with protective covers to prevent personnel from being involved or squeezed. Emergency stop buttons are evenly arranged along the line for emergency disposal.

II. Personnel Safety Protection Technologies (Man-Machine Isolation + Access Control)

The core is to avoid risks such as personnel being collided, involved or squeezed by equipment, building an all-round protection system of physical isolation, intelligent management and emergency support in line with special equipment safety management requirements.

1. Physical Isolation and Regional InterlockingSafety fences, safety doors and access interlocking devices are set up in equipment operation areas with a mechanism of door open, machine stop. Equipment cuts off power automatically when safety doors are opened. Safety light curtains and photoelectric sensors are installed at entrances to trigger full-system emergency stop immediately if personnel enter by mistake.

2. AI Intelligent Monitoring and Personnel IdentificationAI video surveillance and human recognition modules are deployed in the warehouse. Unauthorized entry into equipment operation areas triggers acoustic and optical alarms, voice expulsion, and pushes early warning information to the management background, realizing one-operation-one-authorization management.

3. Emergency Evacuation and Protective EquipmentEmergency stop buttons are arranged throughout the warehouse (on equipment panels, walls and both sides of passages) to support one-click warehouse-wide shutdown. Emergency passages and refuge areas are set up in operation zones. Operators must wear safety helmets, anti-smashing shoes, reflective vests and other protective gear.

4. Operation Specification ControlThe LOTO lockout-tagout system is strictly implemented during equipment maintenance: power cut → lockout → tagout → special personnel supervision, prohibiting live work. Regular personnel safety training is carried out, with post eligibility only after assessment.

III. Comprehensive Safety Protection Technologies (Full-Scenario Coverage)

Covering all scenarios such as cargo safety, equipment operation and maintenance, and system interlocking, it realizes closed-loop management of pre-event prevention, in-event control, and post-event traceability, ensuring the full-process safety of the automated AS/RS.

(1) Cargo Safety Protection

Adapted to the multi-category commodity storage needs of supermarkets, it focuses on preventing risks such as commodity damage, deterioration, and collapse:

1. Temperature, Humidity and Fire MonitoringIntelligent temperature control systems are equipped in fresh and cold-chain storage areas to real-time monitor temperature and humidity data, with automatic early warning and adjustment in case of abnormalities. Smoke detectors, temperature sensors, and flame detectors are arranged throughout the warehouse, linked with sprinkler or gas fire extinguishing devices to prevent fire risks.

2. Cargo Status MonitoringThrough RFID technology or visual inspection, the placement status of goods is monitored in real time. If abnormal situations such as cargo deviation or collapse are detected, an early warning is issued immediately to avoid collisions.

3. Differentiated ProtectionSpecial storage slots are used for heavy and fragile goods, with buffer pads added. The WMS system limits the stacking height and weight of goods to avoid damage caused by extrusion and falling.

(2) Equipment Operation and Maintenance Safety

Ensuring the long-term stable operation of automated equipment and reducing safety risks caused by faults:

1. Real-Time Status MonitoringReal-time collect equipment operation parameters such as motor temperature, vibration, and sensor signals. Through data analysis, early warning of faults is issued in advance, and the load is automatically reduced to avoid fault expansion.

2. Regular Calibration and MaintenanceCalibrate protective components such as sensors, limit switches, and braking systems every quarter; conduct a comprehensive inspection of racks, tracks, steel wire ropes, etc., every year to timely handle hidden dangers.

3. Emergency Fault HandlingEstablish a complete emergency response process for equipment faults and reserve core vulnerable parts. After a fault occurs, maintenance personnel quickly troubleshoot and handle it under the premise of ensuring safety, and start the emergency operation mode to ensure uninterrupted operation.

(3) System Safety Interlocking (WMS + PLC + Equipment)

Realize collaborative linkage of various systems and equipment to eliminate safety loopholes:

1. Multi-Level Authority ControlImplement hierarchical operation authority, and key operations require double confirmation to prevent safety accidents caused by misoperation.

2. Fault Interlocking MechanismWhen abnormalities such as sensor failure or communication interruption occur, the equipment stops immediately and alarms to avoid fault expansion.

3. Digital Twin MonitoringThrough 3D visualization technology, real-time present equipment position, operation status, and safety hazard points, supporting remote real-time management and hidden danger investigation.

IV. Safety Standards and Adaptation Points for Supermarket Distribution Centers

(1) Core Implementation Standards

1. JB/T 9018 "Design Specification for Automated AS/RS"

2. JB/T 11269 "Safety Specification for Aisle Stacking Cranes"

3. GB/T 32828 Safety-Related Standards for Logistics Automation Equipment

(2) Key Adaptation Points for Supermarket Scenarios

1. Multi-Category Differentiated ProtectionStrengthen temperature control protection and flexible anti-collision in fresh areas; add buffer devices and visual monitoring in fragile goods areas; reinforce racks and storage slots in home appliance areas to improve heavy-load protection capacity.

2. Order Peak AdaptationOptimize equipment scheduling plans during order peaks to reduce cross-operation of multiple equipment and lower collision risks; increase the frequency of equipment inspections to ensure protection performance under high-load operation.

3. Mixed Pedestrian-Vehicle Traffic ControlStrictly divide equipment operation areas and personnel operation areas; limit the speed of AGV/AMR robots (≤1.0m/s); strengthen acoustic and optical warnings and AI intelligent monitoring to prevent pedestrian-vehicle collisions.

V. Technical Application Value

1. Safety Risk ControlThe collision failure rate is ≤0.01%, the risk of personal injury is close to zero, and various safety accidents are fully prevented.

2. Reduced Loss CostsThe commodity damage rate is reduced by more than 80%, equipment fault losses are reduced, and the service life of equipment is extended by more than 30%.

3. Balance Between Safety and EfficiencyThe intelligent protection system does not affect equipment operation efficiency, achieving the dual goals of "safe operation + efficient performance", and adapting to the high-frequency and high-demand operation needs of supermarket distribution centers.