Modular local positioning system for logistics centers and warehouses
An effective solution for tracking employee location and ensuring occupational safety at a logistics center, port or warehouse.
Personnel positioning and collision avoidance for warehouses and logistics companies
RealTrac Logistics is a modern solution based on positioning technology. It lets you analyze the movements of personnel, loads and vehicles across a logistics center, identify bottlenecks where delays occur and eliminate their causes, whether it is misuse of working time by personnel or inefficient use of special vehicles.
The solution also lets you set up a forklift collision prevention and control system on site.
A warehouse is a site where loads fall from forklifts, personnel get injured and fires break out. The system helps prevent incidents and evacuate people quickly: the dispatcher always knows who is where.
Tasks solved by a positioning system in logistics
Vehicle location
Locating vehicles and preventing collisions between vehicles and vehicle-pedestrian accidents.
Personnel location
Real-time tracking of personnel location. The RealTrac web client can be accessed from anywhere over a secure connection.
Load falling from a forklift
Detecting a falling load or a forklift collision and notifying the dispatcher for a prompt response.
Goods location
Locating goods in the warehouse with tags on loads and vehicles.
Personnel movements
Tracking personnel movements on site and reviewing their routes for a selected period.
Falling load control
Detecting loads falling from a forklift and notifying the people in charge.
Load handling
Monitoring the movement of personnel and loads to optimize forklift operations and load handling time.
Working time
Recording arrival and departure times, presence in work areas and access levels. Event data is stored on the server for up to 10 years.
The system pays for itself in 6–12 months
Objective data on the movements of personnel and vehicles, idle time and delays provides a basis for optimizing warehouse processes.
RealTrac Collision Avoidance System (CAS): preventing vehicle collisions and vehicle-pedestrian accidents
More about the productProblems it addresses
- Vehicles hitting people.
- Collisions between vehicles.
The personal tag and the antennas on the vehicle exchange data over UWB, no satellite navigation is required: the system works the same way under a warehouse roof and outdoors.
Alarm zones
Attention zone
Warns workers that vehicles or machinery are close by. Used to detect a possible dangerous approach.
- Light signal: indicator on the driver's dashboard, LED on the personal tag
- Sound signal: repeating signal inside the cab
- Vibration: single vibration of the tag
Danger zone
Detects a dangerous approach and draws the workers' attention; can slow down vehicles and machinery.
- Light signal: indicator on the driver's dashboard, LED on the tag, beacon on the cab, flashing side lights
- Sound signal: fast repeating signal inside the cab
- Vibration: repeating vibration of the tag
Emergency zone
Raises an alarm in an emergency or in an extremely dangerous approach; can stop vehicles and machinery.
- Light signal: emergency beacons on the vehicle, LED on the personal tag
- Sound signal: siren and horn on the vehicle
- Vibration: continuous vibration of the personal tag
System components
Personal tags
Determine the position of personnel relative to the vehicle. Alarms: visual signals and vibration.
Operator display in the cab
Gives the operator a visual picture of the situation around the vehicle. Alarms: LED signals and beeps.
Antennas on the vehicle body
Mounted on the vehicle body (4 to 8 units) to detect personal tags.
Optional: a vehicle braking system and a cabinet for charging and issuing tags.
Stopping vehicles and limiting speed
Full stop tests have been carried out on Toyota, Jungheinrich and Linde forklifts.
Emergency engine braking:
- built-in driver detection system (emergency braking);
- built-in emergency braking function on some vehicle types.
Prevents acceleration and limits speed:
- electric accelerator pedal (current limiting);
- fuel supply limiting.
The system works indoors and outdoors
Operator notification of a malfunction
The display in the cab informs the operator that the system cannot perform its functions, for example because a cable is damaged or an antenna is broken. The event is sent over LTE or Wi-Fi to the RealTrac server and appears in the dispatcher interface, so a faulty kit is immediately visible to the dispatcher.
RealTrac CAS advantages
- Not affected by weather conditions (rain, snow, fog).
- Adjustable range of the control zones around the vehicle.
- 360° coverage around the vehicle.
- Automatic warning of the vehicle operator about a dangerous approach: sound and light signals on the display in the cab.
- Automatic warning of personnel about a dangerous approach: vibration of the tag on the helmet.
RealTrac Positioning (RTLS): vehicle and personnel location
More about the productProblems it addresses
- Finding people quickly in an emergency.
- Confirming that no people are in hazardous areas.
- Low personnel efficiency.
Positioning and monitoring of personnel, equipment and assets using GNSS: workers and vehicles are located with an accuracy of 3–5 m (typical GPS/GLONASS accuracy is 5–10 m).
Zonal positioning
Accuracy 20 m. Tag battery life up to 4 years.
Precise positioning
Accuracy 0.5–1 m. Tag battery life up to 7 days.
How the positioning system is deployed
Inside buildings
Positioning in warehouse and logistics complexes inside buildings.
Outdoor area: LoRa
Positioning on the site territory with data transmission over LoRa.
Outdoor area: LTE / pLTE
Positioning on the site territory with data transmission over LTE / pLTE.
System components
Software and control server
Receives and stores data from the process networks; generates data and analytical reports for the dispatcher and authorized personnel; integrates with the customer's other systems.
LoRa / LTE network
A LoRa network is deployed on site, or an existing LTE / pLTE network is used, to collect data from personal and vehicle tags and transmit it to the control server.
Personal and vehicle tags
Issued to personnel and installed on the company's mobile assets; determine the location of the object both outdoors and inside buildings.
Equipment
Personnel, vehicles and equipment on site are located with tags and access points from the RealTrac equipment lines.
BASE equipment line
IP54 enclosure, suitable for use inside warehouse buildings.
PROD equipment line
IP67 enclosure, suitable for outdoor use.
PROD VTAG 7xx vehicle tag
Hybrid tag: BLE (~20 m), UWB (1 m), GNSS (3 m); data exchange with the server once per second, over LoRa up to 3 km; 12–24 V power supply; RealTrac CAS support; PROD VTAG 731 with LTE.
BASE ACC 672 tag locker
Automated issuing and charging of personal tags: charging in up to 2 hours, tag assignment to an employee via the access control system, PIN code or face recognition, battery and tag presence monitoring, from 36 slots.
Software
More about the softwareThe RealTrac system comes with the ready-to-use RealTrac Application Server and client web applications, including workstations for the dispatcher and the engineer, as well as other applications.
The RealTrac API also allows integration with any management systems already in place at the customer's site.
Benefits for the warehouse
Safety
- Prevention of collisions with personnel and mobile equipment in the work area.
- Automated notifications about dangerous approaches between personnel and vehicles.
- Prevention of unauthorized access to and approach to restricted areas and zones.
- Monitoring the presence and absence of equipment and personnel in designated and restricted warehouse zones.
- Fast evacuation of personnel in an emergency: you know who is where.
- Real-time monitoring of personnel, visitors, contractors and vehicles.
- Status monitoring: standing, walking, driving, fallen.
- Notifications about deviations from work regulations and travel routes.
Time management and labor productivity
- Online monitoring of the movements of personnel and equipment with a location accuracy of 5–10 m.
- Time management of the presence of personnel and vehicles at work sites and in designated zones.
- Instant search for personnel and mobile equipment.
- Prevention and investigation of abnormal and conflict situations.
- Analysis of working time use: productive time, idle time, delays.
- Operational management of human and technical resources.
- Identifying the causes of lost working time and optimizing processes.
- Audit of the productive working time of personnel.
RealTrac system advantages
Optimal cost of system implementation
Easy integration with third-party systems and sensors
- Fast deployment and launch of the positioning system in a warehouse environment.
- Higher level of safety for work on the warehouse premises.
- Automatic messages when personnel and vehicles enter the work locations set by the work order, hazardous or restricted zones, and about violations of business processes and access levels.
- Optimized and more efficient use of personnel and equipment working time.
- A tool for objective analysis of how personnel use their working time in the warehouse.