Forkliftaction News, represented by editor Allan Leibowitz, was on the jury of the 2022 IFOY Awards. In the lead-up to the announcement of the winners, we continue to share the jury findings, this week looking at the Special of the Year category.

Synaos, Synaos IMS – Vehicle Localization

What is the aim of all the digitalisation if there are still "blind spots" in the company? One such blind spot is the fact that most of the forklifts that drive around in companies are still controlled manually and are therefore not digitised. With the Synaos IMS - Vehicle Localization system, a camera-based sensor kit ensures their cost-efficient localisation - using state-of-the-art computer vision technology.

Synaos is a software company, but has decided to build a small hardware device as part of a 

new system which works with so-called "markers" as a Localisation-as-a-Service (LaaS) tool. Everything is already included in the price and the detection works to an accuracy of about 25 cm. 

You can create transparency in a flash with Synaos IMS - Vehicle Localization. It helps instantly identify bottlenecks, and detects braking distances or people driving around without a driving order. Even the truck that is always running late can now finally be identified. In short: you can observe fleet utilisation precisely. And a very significant USP compared to the conventional storage method is that the forklift only reports the position where it has driven a pallet; scanning the pallet or the products on it is no longer necessary.

IFOY Test Verdict
The simple, real-time localisation of all types of industrial trucks with the help of this very convincing system helps customers on their way to the complete digitalisation of intralogistics. It is very easy to record fleet utilisation, but also to create heat maps for critical points in the warehouse or optimise warehouse layouts. The basic logic: inexpensive hardware works together with intelligent software. Every industrial truck with a power supply and a mounting option can be equipped with the Synaos IMS - Vehicle Localization sensor kit: it’s a huge market.

Sick, PACS (PAllet Classification System)

Is it a Euro, a Chep, a UIC or perhaps a completely different pallet? Incorrectly identified pallets can cost companies thousands of euros every year in lot deposits. The PACS application from Sick aims to put an end to this by enabling the automatic deposit of different pallet types.

PACS (an acronym for PAllet[2]  Classification System) is a recognition system that uses images to identify the type of pallet. Four pictures of the pallet feet are necessary for this; the fifth picture is taken from above and shows what is on the pallet. The whole thing is usually integrated into the stationary conveyor system directly in the goods receiving area.

Until now, employees had to manually determine whether a pallet was "good" or "bad" when it entered the factory gate - an additional task that is error-prone and resource-intensive. With the PACS deep-learning pallet identification system, customers are given the opportunity to automate this process with a modular system of hardware and software. The financial aspect is the direct benefit of this classification system. There are other benefits, such as the identification of incorrect or damaged pallets which can also lead to damage and expensive downtime of the conveyor system. The system also creates transparent processes by connecting the goods to the load carrier. And finally, no specialised personnel are required to operate the PACS system.

No programming knowledge is required for PACS because the system learns from concrete examples. In this way, Sick is able to make pallet identification comparatively simple for its customers.

Because Sick uses trained neural networks for its solution, the branding of the individual pallet types can be recognised with a high success rate - even if their quality is subject to large deviations. The training process takes these deviations into account, learns them and thus increases the robust evaluation.

Due to its space-saving design, the PACS system can also be integrated in narrow assembly positions. Because Sick uses standard sensor technology for its solution, the system is very cost-effective to maintain and service.

IFOY Test Verdict
With an estimated 500 million Euro pallets in circulation, not to mention the other types, the savings potential through PACS is in the tens of millions. The application range of the very reliable pallet classification system covers a broad spectrum: retail, freight forwarding, automotive, mechanical engineering and many other industries.

Still, DSR (Descent Speed Regulation)

With the Descent Speed Regulation (DSR), Still introduces a unique assistance system for trucks and tuggers that facilitates safe driving on ramps, even with heavy trailer loads. The system monitors and regulates the speed of the vehicle - manually or automatically, depending on the configuration. There are three different versions: DSR Basic, DSR Eco and DSR Premium.

With DSR Basic, the driver activates the system manually via the Still Easy Control operating unit. When activated, a preset maximum speed is maintained, even when driving downhill. The hydraulic service brake is actively activated as soon as the vehicle threatens to go too fast when going downhill. Even if the driver does not depress the brake pedal, the vehicle brakes. 

DSR Eco goes one step further. In this version, the program does not have to be activated manually, but is always on stand-by in the background. It is activated automatically when an angle of inclination is detected. The slope and load are calculated by evaluating the speeds and torques of the drive units and the data from an acceleration and speed sensor. With DSR Eco, a slope indicator is constantly shown on the display. If an incline is detected, the speed is automatically limited to a preset value.

The luxury version, DSR Premium, was nominated for the IFOY Award. Here, in addition to DSR Eco, a load evaluation is also carried out and shown on the display. With DSR Premium, the vehicle regulates its speed when driving downhill depending on the gradient and the load being towed. The speed is therefore not reduced to a predefined value, but optimally adapted to the respective situation. In this way, the vehicle always achieves the best possible performance with maximum safety.

The maintenance-free, hydraulic oil-bath brakes on the front and rear axles operate electro-hydraulically. The brake on the front axle is designed as a brake-by-wire system. The brake demand is registered via a potentiometer on the brake pedal, whereupon the braking process is initiated hydraulically via an electric pressure-reducing valve.

The electrical control of this pressure valve makes it possible to brake very precisely and also to actively intervene in the service brake. Thanks to this technical concept, the DSR system can regulate the speed when driving downhill - even without active intervention by the driver.

DSR reduces the need for the driver to apply the brakes and thus the risk of overheating. In addition, the system monitors driving behaviour, which significantly reduces the risk of unsafe situations.

IFOY Test Verdict
Still Descent Speed Regulation (DSR) is a world first. The unique assistance system supports safe driving on inclines and improves driving characteristics at the same time. Depending on the version, DSR recognises the exact gradient and the current load weight. The speed is then automatically adjusted to the respective conditions. Pulling sometimes heavy loads becomes much safer with this system.