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How can evolving technologies help make industrial work safer and easier for equipment operators?

Advanced driver assistance systems (ADAS) technologies like forward collision warning (FCW) and automatic emergency braking (AEB) are designed to help drivers mitigate crashes in some circumstances. Given their potential to improve safety and reduce serious injuries and fatalities (SIFs), ADAS features are also making their way into industrial equipment like forklifts, tractors, cranes, and other heavy-duty machinery, where they could improve worker safety as well.

According to , there were over 1,000 forklift-related severe injuries reported in 2022-23 in the U.S., leading to 994 hospitalizations and 196 amputations. ADAS technologies in industrial equipment — also known as operator-assistive technologies — could help address some of these types of incidents in the future.

Potential benefits of operator-assistive technologies in industrial settings

Like ADAS technology in on-road vehicles, operator-assistive features in industrial equipment offer a range of potential benefits, such as alerting operators to nearby obstacles and dangers or automatically braking to mitigate potential incidents. Both SAE International and the National Highway Traffic Safety Administration classify such momentary interventions or alerts as L0 features, meaning the driver remains responsible for operation. Features classified as L1 may provide continuous lateral or longitudinal support, such as adaptive cruise control (ACC) and lane keep assist (LKA). Similar support systems are available in industrial applications, although their implementation may differ depending on function and the operational environment.

Like ADAS, operator-assistive technologies use various sensors and control systems to provide, in some situations, additional information or automatically respond to the environment. These systems include, but are not limited to:

• Pedestrian and object detection systems: These systems use cameras and other sensors to detect obstacles and may automatically apply brakes to mitigate collisions, in some situations. Some collision mitigation systems combine camera technology and radar or even lidar sensors to distinguish between objects and humans.
• Driver detection and monitoring: These systems sense the presence (or lack thereof) of operators and their general condition.
• Automated braking or shutoff: In some cases, the system may automatically stop the equipment if an imminent collision is detected. Some systems may limit the traveling speed of the equipment and slow the equipment for pedestrians and objects under specific conditions.
• Blind-spot detection: Operators may receive alerts to objects or people in their blind spots, with the intention of increasing their awareness of surroundings.
• Automated steering and collision mitigation: Some tractors use automated steering systems to stay on course while cultivating, planting, plowing, etc.
• Equipment monitoring and alerts: Some industrial equipment use internal sensors to monitor parameters such as diagnostics, stability, and variable control limits to prevent both accidental and intentional misuse.

Recent advancements in sensor technology, such as LiDAR, radar, and computer vision, and machine learning algorithms continue to improve the capabilities of ADAS and operator-assistive technologies. Network connectivity enables real-time monitoring and remote diagnostics for fleet management, further enhancing the capabilities of operator-assistive technologies in industrial settings.

Potential challenges and limitations for operator-assistive technologies

Implementing operator-assistive technologies in harsh industrial environments can be difficult due to dust, vibrations, extreme temperatures, and other physically challenging conditions, like low lighting, slick floors, tall obstacles, and changing environments (e.g., reconfiguration of stored materials or shelving). Precision sensing systems like LiDAR and computer-assisted vision are key to overcoming these challenges. These sensing systems work together to build an accurate representation of obstacles and potential hazards in the immediate area. They typically use complex software systems to interpret sensor data and respond accordingly. Thoughtful safety analyses and testing may help to demonstrate effectiveness and validate capabilities before deploying this advanced technology. 

The initial investment in operator-assistive technology can be high, and calculating the return on investment can be complex. Calculating ROI requires a detailed examination of existing procedures, including timetables and other operational factors that can be considered costs. Safety analysis plays a role in this calculation when considering the overall benefits of incorporating a system as well as projected effectiveness for the understood use cases. Training requirements are another consideration as operators will need time to learn how to effectively use new systems. 

Once operators are trained, ensuring adoption and compliance with operator-assistive-equipped machinery poses unique challenges among work forces. 

Regulation of operator-assistive technologies may vary

Compliance with safety and operational regulations varies by region and industry. Any new equipment that features operator-assistive technology may need to meet new national or state regulations. While manufacturers do their best to ensure their equipment meets these requirements, it is typically the owner's responsibility to confirm the equipment can be legally used in their business. Business owners must fully understand state and local requirements and laws before implementing any operator-assistive technology. The rapidly changing regulatory landscape in operator-assistive technology adds to the challenge of maintaining awareness and adaptability for compliance.

Adequate training for usage of operator-assistive-equipped machinery is crucial for maximizing its potential benefits. The equipment may help automate certain tasks, but only if operators are properly trained. While manufacturers may supply standardized training materials, these resources might not address the unique safety concerns relevant to a specific user's operations. Developing in-house training documents often requires a risk analysis, thoroughly reviewing logistical procedures, and considering various human factors components.

Once operators are trained, ensuring adoption and compliance with operator-assistive-equipped machinery poses unique challenges among work forces. Operators may need to be trained or re-trained as new procedures are developed or as manufacturers "unlock" new operator-assistive features and technologies with software updates.

Overcoming challenges 

• ADAS Testing: Manufacturers can test ADAS-equipped vehicles and equipment in real-world situations to help ensure they operate properly under a diverse range of circumstances. These tests, when conducted in a controlled environment, can help manufacturers identify issues and improve physical and software systems. They can also help users develop a variety of common scenarios that any equipment operator may encounter, like warehouses packed with crates or construction sites with other operating vehicles. Such testing may also inform internal procedures to further improve the overall safety of operations.
• Human Factors Assessments: Operators are crucial to the safe use of ADAS-equipped vehicles and equipment. They should be thoroughly trained to use the systems and respond to adverse conditions. That means creating a suite of training materials and procedures to help operators learn the proper way to use equipment. Operator understanding and compliance also relies on fine-tuning the human-machine interface (HMI) of a system. User studies based on established HMI research can help reveal opportunities to improve ADAS-equipped systems.
• Safety Case: Systematically evaluating the complex intricacies of a combined human-machine system can help manufacturers develop strategies and systems to mitigate injury and damage. Developing safety cases and conducting safety case assessments can help manufacturers and ADAS developers envision dependencies and identify potential gaps before they become a problem.

Future trends

The evolution of operator-assistive technologies may be enabled through continued technological advancements, allowing systems to become more effective, safer, and easier to use. Manufacturers are developing fully autonomous forklifts and tractors with some equipment already in testing or use. Similarly, some manufacturers are also integrating remote operation capabilities such as the usage of cab-free equipment to remove or reduce human exposure to potentially hazardous situations and environments.

As the industry continues to grow and incorporate advanced technologies, artificial intelligence and machine learning may enable more sophisticated and adaptive technology, including pieces of equipment that can interpret the world around them and respond accordingly. Additionally, high-speed wireless connectivity like 5G networks and large-area wi-fi can help facilitate better real-time data exchange and monitoring. These advancements, though not without their challenges, will support the development of various assistive technologies in industrial applications and serve to supplement human operation and promote industrial safety. 

ADAS technology has come a long way from its early days in on-road vehicles to its current applications in industrial equipment. The potential benefits of operator assistance, including the potential to mitigate or reduce certain incidents, are driving its adoption in industries like warehousing, agriculture, and construction. Additional benefits may continue to be realized through advancements in automation of equipment, including increased efficiency and cost reduction. While challenges remain, ongoing technological advancements suggest further integration of operator-assistive technology in industrial settings, creating safer, more efficient working environments.