The Infinity Forklift Safety Zone System mounts on a forklift’s overhead guard and projects a bright green boundary line onto the floor on the truck’s left, right and rear while it works. Three infrared presence sensors tuned to people watch those same three sides out to 2–7 m (6.5–23 ft). When a pedestrian walks toward the line, that side flips to red and strobes, and a roof-mounted speaker calls out a spoken warning – so the walker sees it and the driver hears it before anyone is in the way.
It’s built for warehouse, distribution and plant safety managers who already paint aisles, hang signs and still see near-misses at rack ends and blind corners. Painted lines stay put; the truck doesn’t. This kit draws the keep-out zone around the vehicle itself, everywhere it goes, and wires straight into the truck’s own 10–80 V DC battery system – no separate power supply, no charging routine, nothing for the driver to remember to switch on.
Everything runs from the one control box on the truck. Nothing installs in the building, and the warning fires whether the forklift is in a rack aisle, at the dock, or out in the yard.
The lights and sensors sit on the overhead guard, so their height is set by the truck. You tune the zone by angle, not by mounting height. The table shows the two ranges you control and what each setting is for.
A typical setup: draw the line at the distance that fits your aisle width, then walk each side with a colleague and adjust the sensors until the red warning fires where you want it. Each sensor watches a 120° field, and three sensors with three lights is the standard load for one control box. Long-body equipment or tow tractors pulling carts are configured to order: extension cables move the lights and sensors out along the body, and where more than three of each are needed the control board is built for it. Send us the body length, the mounting height and the line length you want and we will spec it.
Every component mounts on the forklift’s overhead guard (the roof cage). Here is where each of the nine pieces goes, per the install diagram:
The hub. Every sensor and light plugs into it, and it decides which side turns red and when the voice plays.
One on each side of the guard, on brackets, angled down to draw the floor line where you want it.
Mounted beside the lights on the same three sides and angled outward to cover the zone each light marks.
Faces out so the pedestrian hears it clearly and the operator hears it from the seat.
The wiring harness ties all of that to the control box, and its 3 m (10 ft) power cable runs down to the truck. Power is the forklift itself: the harness lands on the vehicle’s DC battery system anywhere from 10 V to 80 V, which covers electric and IC (gas, diesel, LP) forklifts, tow tractors, order pickers and construction equipment such as excavators. No converter, no separate supply, no charging schedule – the system is live whenever the truck is. The harness has two power leads, positive and negative. Where they land differs by forklift model, so your forklift technician picks the tap point; everything else is bracket-mounted and plugs into the control box. The floor line and the trigger distance are both set by angling the lights and sensors, so there is nothing to program.
The ceiling-mount reality: this is a vehicle system, not a ceiling projector. It has no wall plug and ships without a mains power adapter. To bench-test it or run a stationary demo you need a DC supply in the 10–80 V range – ask us before you order and we will point you to the right one. For a fixed zone on the floor (a dock door, a blind corner, a pedestrian crossing) the right tool is a ceiling-mounted unit: see warehouse safety signage projection or the Laser Safety Line Sign Projector.
Human-body infrared sensors, 2–7 m (6.5–23 ft) adjustable range, one for each watched side.
Dual-color line lights (model 1081E) with 18 W Osram LEDs and mounting brackets. Red line reaches about 5 m (16 ft).
Reads the sensors, switches each light between green and strobing red, and triggers the voice alarm.
Roof-mounted spoken warning, standard English recording. Other languages can be set at the factory on request.
Connects every component to the control box, with a 3 m (10 ft) power cable to the vehicle.
Whole kit rated IP67 and -40°C to 80°C (-40°F to 176°F). Larger kits with more sensors and lights: ask us.
Rack aisles where pickers on foot and reach trucks share the same floor. The zone turns red on the exact side the picker is on.
Line-side deliveries, where operators step back from a workstation into the path of a passing truck without looking.
Rated down to -40°C (-40°F), so the lights and sensors keep working inside the freezer, not just on the loading side.
IP67 for rain, dust and washdowns. Outdoor lots where customers wander between stacks and the trucks feeding them.
Tow tractors and long-body equipment: a configured-to-order kit with extension cables puts the zone around the whole rig.
Order pickers and stock trucks on the sales floor after hours – and around the last customers still shopping.
Our ceiling-mounted safety projectors mark a fixed zone: a crosswalk at a dock door, a “STOP” gobo at a blind corner, a lane line down a main aisle. They win when the hazard never moves, when you need a symbol or a message rather than a line, and when one unit on the ceiling covers a spot every truck passes through. The Laser Safety Line Sign Projector is our higher-output plug-in ceiling unit for that job, and the Infinity SafeGuide Adjustable Laser Line Projector draws a single sharp laser lane line and can also be vehicle-mounted.
The Forklift Safety Zone System marks a moving zone. It wins when the hazard is the truck itself, when the operator’s view is blocked by the load, and when you want the warning to reach both people at once. Its sensors also ride on the truck; our Detection Sensors (radar and camera add-ons) do the opposite – they watch a fixed spot and switch on a ceiling projector when traffic approaches it. Facilities with real pedestrian–forklift overlap run both: fixed zones where the risk is a place, moving zones where the risk is a vehicle. The laser vs. LED line guide and the radar vs. camera sensor guide go deeper.
Tell us your fleet size, truck voltages and aisle widths and we will confirm the right kit count and sensor settings for your floor – and whether a fixed ceiling zone should go with it.
Specifications from the product datasheet, quotation and installation diagram.
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