Logistics Safety AI

Event Gates Logistics Safety AI

LSAI

Event Gates Logistics Safety AI is an advanced industrial vision system designed to enhance safety in busy logistics environments. By combining deep-learning image analytics with real-time monitoring, it detects potential hazards—such as collisions between forklifts, trucks, pedestrians, or falling loads—and intelligently triggers vehicle deceleration before an accident occurs. The system also ensures compliance by monitoring the use of personal protective equipment (e.g., helmets, hi-vis vests) and vehicle safety measures like curtains and wheel chocks, automatically logging safety violations and issuing notifications as needed.

The solution is tailored to high-risk zones like loading docks, sideloading bays, and high-rack corridors, where precise coordination between people, vehicles, and equipment is crucial. It integrates seamlessly with existing infrastructure—such as vehicle restraint systems and automated alerts—without requiring wearable tags or manual intervention. This enables organizations to proactively manage workplace safety, reduce accident risk, and ensure operational continuity—all while collecting valuable video and event data for audit and continuous improvement.

Features

Logistics Safety AI is a VIS solution therefore it has all VIS features and functions where applicable:

• Disconnected solution, deployed to the edge devices on the crane trolley or bridge, does not need internet or corporate network access.
• Proprietary high performance person detection model Event Gates PF, specially trained for top down view in industrial environments.
• Vislet Model Fusion allows detections of multiple models interplay together.
• Built-in trustworthiness features: Heartbeat, Short Term Memory, Emergency Preset of IPIO.
• Logging features including system logs, event logs and optional emailing features.
• All flexibility of regions(ROI), including polygons and multiple regions.
• Built-in mute with IPIO.
• Tracking
• Person counting helps secure unmonitored blind spots.
• UWB based wireless device to slow down vehicles such as electric forklifts or alert individual operators inside the vehicle.

Risk assessment

Forklift–pedestrian collisions

Forklifts and other industrial vehicles often operate in shared spaces with on-foot personnel, creating constant collision risks. These accidents typically occur in intersections, corners, or blind spots where the operator’s visibility is limited. Even when lanes are marked, distractions, poor lighting, or noncompliance with walking routes can lead to serious or fatal accidents. Logistics Safety AI continuously monitors these zones and detects the presence of both pedestrians and vehicles in proximity, enabling early intervention such as deceleration triggers or alerts before a collision occurs.

Truck drivers reversing into docks without visibility

Pop up barrier

When truck drivers approach loading docks in reverse, they often lose visual contact with the area behind the vehicle. This becomes extremely dangerous if pedestrians or forklifts are moving or working between the dock and the trailer. Human presence in this blind spot is nearly invisible to the driver, especially if mirrors or cameras are not used properly. Logistics Safety AI detects humans in this zone during reversing maneuvers and can trigger alerts, vehicle restraints, or automatic deceleration to prevent deadly accidents.

Obstructed vision during side loading/unloading

Side-loading operations, particularly in narrow bays or tightly packed environments, reduce the forklift operator’s visibility of the space behind the truck. This is especially hazardous when workers are performing tasks in those areas or passing through unexpectedly. Even with mirrors and training, obstructions caused by trailer walls, loads, or warehouse structure can hide human presence. Logistics Safety AI identifies these occluded zones and monitors for pedestrians near side-loading operations, generating warnings or logging events when danger conditions are met.

Falling objects caused by order pickers

In logistics centers with high-rack storage, order pickers—manual or robotic—operate at heights to retrieve or place items. Improper handling or unstable stacking may cause packages, boxes, or equipment to fall into adjacent aisles or onto unsuspecting personnel below. These accidents are difficult to anticipate and often go undocumented. Logistics Safety AI uses spatial awareness to detect nearby people, identify hazardous object motion, and log or alert on events where falling objects may pose a safety risk.

Personnel working behind or between goods

In some loading scenarios, workers position themselves behind or between stacked pallets or cargo to inspect, adjust, or prepare items for transport. These individuals are often fully or partially obscured from the forklift operator’s view, particularly when large items block lines of sight. This creates a high-risk situation where someone may be struck or pinned during routine loading or unloading. Logistics Safety AI monitors these high-obstruction zones and detects human presence even when visibility is minimal, helping prevent crushing or impact injuries.

Non-use of personal protective equipment (PPE)

Warehouse and logistics operations frequently require the use of safety gear such as high-visibility vests, helmets, or protective footwear. When this gear is not worn, workers become less visible and more vulnerable—both to vehicle operators and to automated safety systems. In dimly lit or fast-paced environments, missing PPE can be the difference between detection and accident. Logistics Safety AI includes PPE compliance monitoring and can detect missing or incorrect gear in real time, issuing alerts or logging violations as needed.

Unsecured vehicles at loading bays

Trucks parked at docks must be properly restrained to prevent unintended movement during loading or unloading. If wheel chocks or dock-lock systems are not used—or are removed too early—the vehicle may shift unexpectedly, causing serious injury or damage. This risk is especially high when heavy forklifts are entering or exiting the trailer. Logistics Safety AI verifies the presence of safety measures like wheel chocks or locks and checks whether vehicle movement occurs in an unsafe state, enabling automated alerts or integration with restraint systems.

Blind spot junction

Congestion in high-traffic corridors

Logistics environments often include narrow aisles or intersections where pedestrians, forklifts, AGVs, and order pickers converge. These areas become safety-critical due to the density of movement and the complexity of interactions. Visual obstructions, noise, and fast-paced operations make it hard for workers to anticipate others’ movements. Logistics Safety AI detects objects and people in shared zones, identifies risky proximity or convergence, and supports alert systems to reduce the chance of collisions or unsafe crowding.

Unnoticed persons in restricted or automated zones

Certain warehouse zones are designated for robots, AGVs, or heavy equipment and are not intended for human access. However, unauthorized or accidental entry by workers into these areas can result in near misses or serious injuries. Traditional access control measures (like warning signs or physical barriers) are not always effective. Logistics Safety AI continuously monitors these zones for unauthorized human presence and can trigger alarms, stop automation, or log the intrusion for further action.

Solutions

Forklift – pedestrian proximity

Forklift–pedestrian proximity detection

This solution dynamically links a virtual safety zone to each detected forklift. The region moves with the vehicle and is continuously evaluated for overlap with detected pedestrians. If a person’s bounding box intersects with the forklift’s dynamic zone, VIS can trigger alerts or initiate automated slow-down actions on the vehicle. This approach is particularly effective in large operational areas and high-traffic junctions where blind spots exist for both the forklift operator and nearby pedestrians. Overhead or wall-mounted cameras provide the external viewpoint needed to observe both parties clearly and mitigate blind-zone risk.

Co-operation area protection

Co-operation area protection

In designated co-operation zones—where vehicles and people are expected to work in close proximity—fixed virtual regions are configured to monitor shared activity. When both a vehicle and a person are detected within the same region, the system triggers an alert or deceleration action to reduce the likelihood of a collision. This solution is ideal for loading/unloading platforms, sorting areas, or compact warehouse zones where humans and machines must operate side by side.

Multi-angle region grouping

Counter region

VIS supports grouping regions from multiple camera views to create a logical shared zone, even when individual cameras cannot cover the entire area. This allows risk detection in spatially complex environments—such as both sides of a truck, or the front and rear of an order picker—where visibility from a single viewpoint is not sufficient. Region groups are evaluated collectively to identify cross-camera presence of people and vehicles, enabling a more complete and accurate understanding of the situation.

On-vehicle threat detection

For vast or open-air logistics environments where static infrastructure is limited, VIS can operate on vehicle-mounted cameras to detect people or hazards directly from the moving vehicle’s perspective. This mobile setup allows real-time threat detection in container yards, outdoor storage, or large indoor areas with dynamic layouts. It enables smart forklifts, tuggers, or other logistics vehicles to become self-aware of their surroundings and respond to nearby human presence.

Perimeter tracking and person counting

In restricted-access zones or areas without full camera coverage, VIS uses perimeter-based tracking and entry/exit counting to maintain situational awareness. By monitoring movement across defined entry lines and keeping a live count of people present within a closed area, the system can infer whether personnel remain inside—even if visual contact is lost. This is critical in sealed docks, trailer interiors, or back-of-rack zones where direct monitoring is difficult but worker presence must still be accounted for.

Information on video section displays the person (object) count inside a specific region.

Use Cases

Side loading bay

Side loading bays

Side-loading bays, common in automotive and high-throughput logistics operations, demand precise coordination between trucks, forklifts, and nearby personnel. One of the main risks in these areas is the forklift operator’s limited visibility—especially on the far side of the truck—combined with frequent, often unauthorized, pedestrian presence.

Event Gates Logistics Safety AI mitigates these risks through a dual-camera setup, monitoring both sides of the truck. If a pedestrian is detected in a monitored zone while a forklift is active, the system triggers a voice alarm and slows the forklift automatically. Additionally, traffic lights—red and green—guide the operator, signaling when it is safe to proceed.

Side loading bay

Forklifts are equipped with UWB receivers, and mobile transmitters enhance position accuracy and enable real-time communication between vehicles and the AI system. For extended oversight, an optional email alert system sends violation reports—complete with attached video evidence—to designated safety personnel.

Beyond detecting vehicles and people, the system also identifies chocks, open truck curtains, and PPE compliance (e.g., helmets, hi-vis vests). This ensures trucks do not move while unsecured and that safety protocols are followed before loading or unloading begins.

With Logistics Safety AI, side-loading bays are transformed into actively managed, high-visibility zones where safety and operational efficiency go hand in hand.

Loading docs and ramps

Loading dock

Loading docks are critical transfer points where trucks reverse into position so forklifts can load or unload goods directly through the back of the trailer. The dock entrance typically includes a raised platform, and personnel work on the indoor side to prepare or handle materials. During loading operations, forklifts frequently move in and out of the truck from this platform.

One of the most serious safety risks arises when a truck approaches the dock in reverse while personnel are still present in or near the path of the vehicle—especially near the dock entrance or between the dock and the trailer. This can occur if workers are finishing up tasks, inspecting the ramp, or simply passing by. Since truck drivers cannot see behind their vehicle during this maneuver, a person in the danger zone may go unnoticed until it’s too late.

Docking ramp

To address the risk of trucks reversing into occupied areas, Logistics Safety AI monitors the space in front of the dock using one camera mounted above the dock door, facing outward. This perspective allows the system to detect both incoming trucks and any personnel present in the approach zone.

Two conditions must be met for an alarm: a person must be detected in the predefined danger zone and a truck must be reversing or present. If only one of these elements is detected—either a person or a truck—the system does not raise an alarm, but can still activate a separate non-critical output. This output can be used by external automation systems, for example to display ramp status, log activity, or prepare preemptive safety measures without triggering a full alert. This layered approach helps balance safety with operational flexibility.

When both conditions are met, the system triggers configurable countermeasures, such as flashing lights, sound alarms, or an automatic barrier that rises to block the truck’s path. These interventions aim to stop the vehicle before it reaches the dock and ensure the safety of anyone in the area.

This setup works autonomously, without requiring manual confirmation or sensor input from the truck. It’s especially suitable for environments where drivers or visitors are unfamiliar with the site and may not expect pedestrian activity near the loading zone.

High rack corridors

High rack corridors

High rack corridors—with their narrow lanes and elevated storage—present persistent safety challenges such as vehicle-person collisions and falling objects. Event Gates Logistics Safety AI addresses these risks with real-time monitoring and automated response features tailored to high-density warehouse environments.

The solution relies on cameras installed at both ends of the corridor. Each camera operates independently to detect vehicles and persons; however, critical risks may still occur—for example, a vehicle approaching from one side while a person is present at the opposite end, or a vehicle obstructing the camera’s view. By grouping both cameras into a shared region using the region groups feature of VIS, VIS creates a unified context, allowing it to detect and respond to such risks holistically.

The system reliably identifies unsafe interactions, such as climbing, crossing between racks, or two-person vehicle use. It also monitors for the presence of protective equipment like helmets and hi-vis vests. When a risk is detected, sound and light alarms notify both operators and individuals in the corridor, helping prevent incidents before they occur.