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| Instrumented lift truck with operator warning system |
Background
A common danger in the mining, agriculture, and construction industries is that mobile equipment is often unknowingly operated in an unsafe manner. Operator errors are frequently the result of inadequate training, complacency regarding equipment operation, and taking shortcuts. Many times an operator unknowingly operates the equipment beyond its safe operating limits or fails to recognize dangers in the work environment. Unsafe operation can result in injuries and the deaths of both drivers and pedestrian workers; over 100 fatalities and 20,000 lift truck injuries occur yearly in the United States. Seventy percent of these accidents were caused by operator error. In 2000, the leading causes of lift truck fatalities were lift truck overturns (23%), pedestrians and workers struck by lift trucks (39%), and falls from lift trucks (10%). During 1999-2003, over 181 lift truck traumatic injuries were recorded at mining operations where seven or more fatalities had already occurred.
NIOSH, in collaboration with the North American Coal Company (NACCO), the manufacturer of Yale and Hyster lift trucks, is investigating ways to reduce the high number of injuries and deaths related to dangerous lift truck operating practices. A prototype forklift operating warning system (FLOWS) was developed by NIOSH researchers. This system continuously monitors the critical operating parameters of a lift truck to alert the operator when the vehicle is being operated unsafely. When a critical operating parameter is exceeded, a digital voice warning message is activated that can be heard by both the lift truck operator and any nearby workers. The warning can, for example, alert the operator when he or she is traveling or cornering too fast, nearing pedestrian workers or obstacles, lifting too heavy of a load, and approaching the edge of a loading dock. The sensor-based monitoring system can also be used a tool to improve lift truck operator training, evaluate training programs, and identify areas in need of additional training.
Potential Outcome
The expected impact of this research will be to reduce the 20,000 yearly lift truck accidents in the United States by 20% by 2010.