Even with full concentration, it is often challenging for pallet stackers to correctly assess a dangerous situation: How big is the current total load? How much higher can the load be lifted? Which speed is suitable for the load weight and lifting height?

An assistance system for load control has the answer to exactly these questions; it alerts the operator and can even intervene if necessary. Such a system makes load handling with pallet stackers easier and safer. The driver receives clear optical warning signals on the large display as well as acoustic warning signals. If the actual load weight exceeds the maximum load capacity, the lifting function is automatically blocked.

Employees often have little experience when it comes to handling large, heavy and long goods with different dimensions. If the operator makes a mistake when calculating residual load capacity, this can quickly become a safety risk for them or other employees in the warehouse. It is extremely labor intensive to use a payload diagram to calculate the height up to which the goods can be lifted. But if employees only rely on their intuition, the truck can topple in the worst case scenario. Operating errors can also quickly occur when transporting or maneuvering the load, for example because the driver drives with a lifted load or the tiller is screwed in too suddenly.

The system actively controls the driving speed and acceleration based on lifting height, load weight, and steering angle, following a risk-dependent sequence:

1. Warning when approaching the limit area: A yellow warning symbol indicates that the load limit is approaching, and a warning tone is heard simultaneously. On the display, the pallet stacker operator sees the current height and the maximum height allowed by the current load weight.
2. Warning when the residual capacity is reached: When the load limit is reached, a warning appears that the operator must confirm to continue handling the goods. Therefore, he is aware that safe handling is no longer guaranteed.
3. Warning and blocking of the lifting function: If the operator exceeds the payload, a red warning symbol appears, and a warning tone is heard. In addition, the lifting function is disabled.