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AisleCop Forklift Safety System for Robotic Workcell Area
Synchronized pedestrian gates help manage multi-directional crossings in a manufacturing facility
Get QuoteThe Scenario
A forklift operator must cross and partially block a shared lane to unload a pallet conveyor. Pedestrians and other forklifts use that same lane, and workers on foot can pass dangerously close to the machine while it operates. The risk of a serious accident is high.
Configuration and Operation
We engineered a custom safety solution using three AisleCop® forklift gates, two AisleCop® pedestrian gates, overhead sensors, guardrail, and floor markings. Guardrail and floor markings define the pedestrian and forklift lanes approaching the work zone, and the gates rest in a position that keeps cross traffic flowing normally.
The forklift operator triggers the system with a pull handle. Alert lights on the gates flash and overhead sensors scan for approaching traffic. When the intersection is clear, the two pedestrian gates swing out and a pair of forklift gates lower to span the large cross-traffic lanes. A third forklift gate then raises to open the work zone, and the forklift enters to unload the conveyor.
The gates hold their positions throughout the unloading process. When overhead sensors detect that the area is clear, the gates reset and cross traffic safely resumes.
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Pedestrian Gates for Conveyor Unloading
Guards a pedestrian aisle crossing where forklifts load and unload a stretch wrapper.
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Dual Purpose Pedestrian Gates
Pedestrian-priority setup — two parallel foot aisles cross one forklift aisle.
AisleCop® Forklift Safety System Components
This system may utilize a combination of the following components to help manage a dangerous intersection or aisle.
Pedestrian Gates
These gate systems come with push-buttons as the standard activation method, with bright flashing red LED lights on the top of the arm for further visibility. They swing easily open and will stop when they meet an obstacle. They synchronize with motion sensors and any forklift gates utilized with the system.
Forklift "Boom Arm" Gates
Forklift gates raise and lower as triggered by various processes - the activation of a pedestrian gate, controls via motion detection, pull switches, ground loops, or other methods as needed per application.
Guard Railing
Steel guard rails are not necessarily part of every forklift safety system, but are frequently used as part of the system to help manage and separate foot and vehicle traffic. Guard rails can be specified from ultra-heavy-duty to simple hand rails, to fit the needs of a particular application.
Motion Sensors
The typical AisleCop® system utilizes motion sensors to detect foot and vehicle traffic. These sensors can be mounted on either the forklift, on pedestrian gates, on walls, on racks, on guard rails, or at other spots as needed to monitor the protected zone.
AisleAlert™ Floor Warning Lights
AisleAlert™ adds a visual warning layer where gates aren't practical. Ceiling-mounted sensors scan the intersection and trigger a bright LED light that flashes directly down onto the floor at the center of the crossing, where both drivers and pedestrians will see it. The system triggers only when traffic converges from at least two directions, so it stays dark until there's an actual collision risk. Available in 2-way, 3-way, and 4-way configurations with a red or blue light.
AisleCop® systems are safety tools that are designed to help define and control access to forklift aisles. They do not provide 100% protection from industrial traffic accidents, and they are not a substitute for comprehensive workplace safety programs or procedures. AisleCop® gates direct and manage traffic flow but are not impact-resistant barriers and will not stop forklifts or other industrial vehicles.
The effectiveness of any AisleCop® system depends in part on factors outside the control of Cisco-Eagle, including but not limited to other critical factors, such as system and equipment maintenance, driver compliance, and pedestrian and individual compliance, enforcement of crossing lanes, and accurate assessment of safe crossings conditions. Users are solely responsible for these and all other safety measures.
Use of an AisleCop® system is at the user’s own risk. Users must follow all safety instructions, warnings, and applicable laws. AisleCop® systems are intended for professional environments and should be operated only by trained and qualified personnel. No representation is made or implied that the system can prevent all accidents, injuries, or losses.