Design on safety
September 5th 2003 Truck manufacturers are having to face up to changing attitudes, argues Chris Booth, Joint MD at Still Materials Handling
Accidents involving forklift and warehouse trucks have regrettably been an accepted fact of industrial life for many years. But, STILL contends, it need not be so. In an industry as hard-pressed as materials handling, investment in safety design has not always been near the top of the priority list. Speed of operation and low acquisition and running costs have all too often come before product refinements which make the workplace a safer environment
Three decades of development STILL took a different view as far back as the 1970’s however, when it introduced the first of the R60 electric counterbalance models. Research had shown that in over 60% of all forklift truck accidents, the truck overturned - often with catastrophic consequences for the driver, who was usually totally unprotected. STILL’s designers reasoned that if they could produce a truck that was almost impossible to overturn, they would make a real contribution to safety at work. Radical re-design They achieved this by a radical redesign of the underpinnings of their 4-wheel electric counterbalance truck to permit the battery to be mounted low in the chassis and within the wheelbase. STILL’s experience in electric motor technology helped here, with new, lightweight but powerful motors mounted transversely at the front
The result was indeed a truck that was almost impossible to overturn, and this was demonstrated at a 1982 Press Event in Hamburg when it was placed on an angled platform and raised until it was over 45°
In practical terms however, this lateral stability translated into safety a truck that not only accelerated faster than just about any other truck on the market at the time, but could also be driven at higher speeds around bends - making the most of its powerful new drive motors
The rest is history - the STILL R60 has been steadily developed to the point where the current R60 range literally bristles with usable technology. An example is the rear axle design: by raising the pivot point of the rear axle and restraining its movement with a torsion resistant mounting, STILL has achieved high lateral stability without having to resort to sensors or moving parts
‘Deadman’ system In the early 1980’s STILL introduced a major advance in safety design: control technology that effectively made the accelerator pedal a deadman control. The truck interpreted the pedal position literally - so if the pedal was released, the truck would stop. The brake pedal became virtually redundant. Not only did this revolutionise safety but it also made for a more economical machine - and STILL capitalised on this by developing a sealed for life, oil-immersed brake that never needs servicing and is now featured across the current counterbalance range
Tiller operated trucks Even on the tiller operated machines, the experience gained in the counterbalance trucks has been applied to give high lateral stability, brisk performance and a drive system that features load-sensitive traction for the driven wheels
Tiller arm design is a major safety element in pedestrian operated equipment and here, STILL has developed a new profile that ensures that the safety impact plate remains facing the operator even when the arm is near vertical. Education The driver/operator is an essential component in industrial truck use and here, education is vital. It is particularly important in such simple matters as the wearing of seat belts. Drivers are notoriously reluctant to use anything they think affects freedom of movement, particularly when they are on bonus schemes. However, employers are now required to address such safety aspects and ensure that drivers understand that they are required to use the safety aids provided. Refusal to wear protective headgear, eyewear and toe protection is a disciplinary matter and seat belts (where specified) fall into that category
Ergonomics - reducing Repetitive Strain Injuries (RSI) Personal injury issues increasingly centre on ergonomics, with repetitive strain injuries (RSI) and back problems costing industry hugely each year. Good visibility, convenient control layout, low noise levels, easy operator access and a comfortable and supportive seat are essential to avoid fatigue related incidents
Extensive ergonomic research has resulted in a standard control layout for STILL counterbalance trucks and some innovative solutions in its warehousing products. For example the SU rider pallet truck and derivatives can be operated in seated or stand-on mode and by applying modern ergonomic design principles, 95% of all operators, male or female, can achieve a near-perfect operating posture
This particular innovation won the FLTA 2003 Ergonomics Award. The STILL FM reach truck uses a similar approach where the floor-plate and seat position can be adjusted electrically to ensure that operators of any height or weight can achieve the optimum line of visibility
Swivel seat reduces back strain Many STILL counterbalance trucks are available with a swivelling drivers seat that allows the operator to reverse in comfort
This, allied to optional joystick control has been shown to substantially reduce driver fatigue. This too, won STILL the FLTA Ergonomics Award, in 2002
External design For years a significant factor in motor car safety design, STILL has adopted the smoothly contoured external profiles that not only make the truck pleasing to the eye but, by obviating the sharp profiling helps reduce the incidence of impact and consequent personal injury or property damage
Ongoing safety development By majoring on safety issues from the drawing board stage, STILL has developed a range of machines that are as safe as possible in use. Designs continue to be improved as new technology evolves and new problems have to be dealt with. More articles from Still Materials Handling: | 
