Reducing collision risk in narrow aisles: HUBTEX launches Clear Aisle Assist

In narrow-aisle warehouses, multidirectional forklifts often operate with minimal safety clearances. Collisions with protruding loads therefore pose a constant safety risk. To effectively minimise this risk, HUBTEX has developed the patented Clear Aisle Assist – a laser-based sensor system that detects protruding loads at an early stage, alerts the driver and automatically reduces vehicle speed when required.

Lines of sight in narrow aisles: The sensors monitor the rack system and detect protruding loads

Challenges in narrow aisles: minimal clearance, limited visibility

HUBTEX multidirectional sideloaders are frequently used in narrow-aisle warehouses. To maximise storage capacity, these vehicles operate within guidance systems that allow very limited safety clearance – often less than 100mm on each side. While this increases space efficiency, it significantly restricts the driver’s visibility.

The situation becomes particularly critical when long items are stored at an angle or when neighbouring loads are inadvertently displaced during retrieval. In such cases, parts may protrude into the aisle and aren't always visible in time from the cab, especially on the engine side. This can result in contact and cause costly damage to the chassis, battery, cab or rack system. In the timber, metal and general industrial sectors, where hundreds of movements are carried out daily, this scenario is commonplace.

Detailed view of the compact integrated sensor and protection unit on the vehicle chassis of a PHOENIX multidirectional sideloader

Patented solution: laser-based monitoring

To mitigate these risks, HUBTEX has developed Clear Aisle Assist, which monitors vertical danger zones along the rack system and reacts automatically when required. The system uses Lidar sensors to analyse vertical planes in the vehicle’s surroundings.

Depending on the vehicle configuration, sensors are mounted in suitable positions and scan both forwards and in reverse. This enables early detection of protruding loads, regardless of whether the forklift enters the aisle facing forwards or backwards. The monitored area dynamically adapts to key parameters such as speed, lift height and vehicle configuration, allowing precise, needs-based detection of potential collision zones without adding to the driver’s workload.

Classification: Clear Aisle Assist doesn't replace personal protection technology; instead, it supplements existing systems by providing collision protection for loads protruding from rack structures.

Operating principle: The sensor detects misaligned item 4, alerts to the danger and slows down the vehicle

Now available for the PHOENIX series

When an obstacle is detected, the system initially issues a warning. If necessary, it then automatically reduces vehicle speed to prevent contact or minimise its impact. The objective is an assistance system that enhances driver awareness while maintaining efficient material flow in confined warehouse layouts.

“Our aim was to develop an assistance system that actively supports the driver without adding extra burden,” says Michael Röbig, Head of Product Management at HUBTEX. “Clear Aisle Assist recognises dangerous situations early and, if required, not only warns the driver but also automatically reduces vehicle speed.”

The Clear Aisle Assist is now available for the PHOENIX series and complements existing personnel protection scanners by offering additional protection against goods protruding into the aisle.

For further information, see www.hubtex.co.uk.