The TK300 Al Anti-collision System is a forklift safety solution specifcally designed for industrial forklifts. Through cameras and inteligentalgorithms, it can quickly and accurately identify pedestrians, enabling realtime detection of people in front of and behind thevehicle. When a potential collision risk is detected, the device will issue an alarm, control the vehicle to slow down and apply thebrakes, and also detect and remind the driver of behaviors such as smoking, making phone calls, and feeling drowsy.
Driving Safer, Smarter Operations with AI Anti-Collision Technology
Modern warehouses are evolving. With the push for greater automation and tighter delivery schedules, safety can no longer be an afterthought. Enter the AI-powered anti-collision system: a revolutionary upgrade to traditional forklift safety solutions. Leveraging advanced sensor fusion, computer vision, and machine learning, these systems redefine how safety is implemented in warehouse operations.
In this blog, we explore how AI anti-collision systems work, why they matter, what makes them unique, and how they align with today’s smart factory standards. If you’re a safety-conscious warehouse manager or logistics tech enthusiast, this is a must-read.
Understanding the Role of AI in Collision Prevention
Why Forklift Safety Needs an Upgrade
Forklifts cause thousands of injuries and damages globally each year. As warehouses scale, the probability of human error increases. Traditional alarm systems and mirrors offer limited awareness. AI adds predictive intelligence, real-time tracking, and dynamic response.
Smart Functions That Redefine Warehouse Safety
DMS: Driver Monitoring System
Using an infrared camera mounted on the A-pillar or dashboard, the system monitors driver behavior.
Detection Capabilities:
- Yawning: Light to severe fatigue levels
- Smoking: Finger or mouth-based detection
- Phone Calls: Recognizes hand gestures near mouth or ear
Performance:
- Detection Rate: ≥90%
- Accuracy: ≥95%
BSD: Blind Spot Detection
BSD uses front, side, and rear cameras to track people and vehicles in real-time. Perfect for preventing:
- Corner collisions
- Pedestrian impact
- Tight-turn crashes
Specifications:
- Daytime detection distance: ≥10m
- Night detection: ≥8m
- Detection Rate: ≥90%, Accuracy: ≥95%
Practical Use Cases in Modern Warehousing
Scenario 1: Tight Dock Maneuvering
A forklift approaches a blind loading dock corner. The side forklift camera system detects a worker and sends an instant visual and audible alert to the driver. Vehicle slows automatically.
Scenario 2: Fatigued Driving Detection
During late-night shifts, the driver is detected yawning repeatedly. The system triggers a warning and logs the event for supervisor review.
Scenario 3: Line Crossing Alert
A pedestrian walks into a restricted zone behind a reversing forklift. BSD rear camera triggers instant alerts with zone mapping overlay.
These real-world cases highlight how AI isn’t just smart—it’s essential.
Installation, Maintenance, and Integration
Easy Deployment
- Plug-and-play components with GX12 aviation-grade connectors
- Compatible with most forklift brands and models
- Optional vehicle control harness enables braking and steering control
Maintenance-Free Intelligence
- Internal synchronization, automatic white balance, infrared night mode
- External control via SD/OTA for firmware upgrades
- Optional expansion: CAN, RS232, 4Ω horn
Environmental Specs
- Operating Temp: -20℃ to 60℃
- Storage Temp: 25℃
- Humidity: 0~95% non-condensing
Benefits You Can’t Ignore
Boosted Safety Compliance
- Supports ISO standards and CE/FCC/ROHS certifications
- Reduces incidents, insurance claims, and operational liability
Enhanced Operational Efficiency
- No manual intervention needed for minor collision prevention
- Improves driver focus by automating risk alerts
Real-Time Data and Visibility
- Frame Rate: 720P25fps/30fps
- Recordings and analytics for safety auditing
- Data rate: 10Mbps/5Mbps for wireless systems
Inside the AI Anti-Collision System: Hardware and Software Overview
What Makes Up the System?
| Component | Specification |
|---|---|
| AI Host | Quad-core ARM Cortex-A7 and RISC-V MCU; 234x154x60mm; 25W power usage |
| Cameras | 720P AHD, 120° angle, infrared, up to 4 BSD & 1 DMS |
| Display Monitor | 7-inch CVBS screen, 450cd/m2 brightness, waterproof IP67 rated |
| Positioning Module | GPS + Beidou dual-mode |
| Connectivity | 4G (Full Netcom), WiFi & Bluetooth dual module, GX12 connectors |
| Others | Waterproof cover, SD card, SIM card, vehicle control harness (optional) |
System Highlights
- Detection Distance: Up to 10m (day), 8m (night)
- Response Time: Real-time alerts under 1 second
- Waterproof & Durable: IP67 rating on core components
- Smart Protocol: HTTP communication, 4G transmission
| System Parameter | Products | Product Dimensions (mm) | Weight (g) | Material | Color |
|---|---|---|---|---|---|
| General Information | AI Host | 234x154x60 | 1.5 | Aluminum alloy | White |
| Monitoring Cameras | 53x35x54 | 0.2 | Zinc alloy | Black | |
| Horn | 7×5.5×2.5 | 0.7 | Plastic | Black | |
| Vehicle Control Wiring Harness (Optional) | 12x7x4 | 0.85 | YGZ silicone rubber | Black | |
| Monitor (Optional) | 205x140x25 | 0.05 | Plastic | Black |
| Electrical Specifications | Power Supply | Power Consumption (W) | Input Voltage Range (V) | Current Consumption | Connector Type |
|---|---|---|---|---|---|
| 12V, 3A | 25W | 12V | 2V | GX12 |
| Communication | Protocol | Frequency Range (Wireless System) | Data Rate |
|---|---|---|---|
| http | 4G | 10Mbps, 5Mbps |
| Environmental Specifications | Operating Temperature | Storage Temperature | Humidity Range | Protection Level |
|---|---|---|---|---|
| -20°C~60°C | 25°C | 0~95% without condensation | IP67 |
Camera Attributes and Detailed Information
| Product | Camera |
| Module Type | 2-megapixel 4-in-1 Wide Dynamic Coaxial HD Surveillance Camera Module |
| Detection Distance | 10m |
| Detection Angle | 120 degrees |
| Waterproof Rating | ip67 |
| Sensor Type | 1/2.9″GC2093+FH8550M |
| System Standard | PAL/NTSC |
| Effective Pixels | 1920(H)x1080(V) |
| Minimum Illumination | 0.01Lux@(F1.2, AGC ON), 0LUX with IR |
| Day and Night Mode | External Control (Default)/Automatic/Color/Black and White |
| Synchronization Method | Internal Synchronization |
| Frame Rate | 720P25fps/720P30fps |
| Video Output | AHD |
| Exposure Control | Brightness/Exposure Mode/Gain |
| White Balance | Automatic Tracking White Balance |
| Infrared Mode | Day and Night Mode |
| Video Settings | Contrast/Sharpness/Saturation/Digital Noise Reduction/Video Standard/Wide Dynamic Range |
Attributes and Detailed Information of the Display Screen
| Product | 7-inch Waterproof Monitor |
| Shell Material | Aluminum alloy shell appearance |
| Waterproof Rating | IP67 |
| Brightness Contrast | 450cd/m2, 500:1 |
| Input Signal | CVBS |
| Input Voltage | 12V~32V |
| Color Standard | PAL/NTSC |
| Flip Function | The video screen can be adjusted up, down, left and right. |
| Overall Accessories | Display screen, connection cable, sunshade, bracket |
Functional Parameters
| Subclass | Project | Specifications |
|---|---|---|
| SOC Chip | CPU | Quad-core ARM Cortex-A7 and RISC-V MCU |
| NPU | 2.0Tops | |
| Video | Video Output | One-way CVBS signal |
| 4G Module | Supported Network Segments | 4/7-mode full Netcom |
| Positioning Module | Supported Types | GPS + Beidou dual-mode |
| WIFI Bluetooth Module | Integrated WIFI and Bluetooth Module | WiFi + Bluetooth dual module |
| Coding Format | Video | H.264, maximum bit rate 4×1080P×25fps |
| Audio | MP3 | |
| Upgrade | Upgrading Method | SUB/SD card/OTA (needs to be used with 4G) |
| USB Interface | It is used to connect to a computer for file transfer and upgrading. | |
| Expansion Interface | Ethernet | 1×10/100M Ethernet |
| RS232 | 1×RS232 | |
| CAN | 1×High-speed CAN, with a 120Ω resistor included by default | |
| Horn | Supports an external 4Ω3W horn | |
| LC Interface | Reverse Gear | High level is valid |
DMS (Driver Status Detection) Function Module
installed on the A-pillar/centralcontrol panel, the monitoring of the driver’s status is achieved. lt mainly includes theThrough a single infrared camerafollowing function modules, and the function descriptions and indicators are shown in the table as follows:
| Category | Subcategory | Function Description | Detection Rate | Correct Detection Rate |
|---|---|---|---|---|
| Fatigue | Yawning | Scalable to support light/moderate/severe levels | ≥90% | ≥95% |
| Abnormal Behavior | Smoking | Supports holding a cigarette with two/five fingers or having a cigarette in the mouth | ≥90% | ≥95% |
| Making a Phone Call | Supports making a phone call near the mouth/near the ear | ≥90% | ≥95% |
BSD (Blind Spot Detection) Function Module
Through the cameras instaled at the front/front letfront rightrear of the vehicle, it monitors the approaching situation of pedestrians/non-motor vehiclesin the blind spots around the vehicle body, and timely qives prompts to the driver and the approaching targets. The descriptions of its main functions andindicators are shown in the table as follows:
| Category | Subcategory | Function Description | Detection Rate | Correct Detection Rate |
|---|
| Overhead View | Left/Right/Rear | Detection distance is ≥ 10m during the day and ≥ 8m at night | ≥90% | ≥95% |
ACCESSORIES LIST
• Camera
| Name | Specification Model | Quantity |
|---|---|---|
| DMS Camera | 720P AHD, Aviation Female Connector GX12, with Infrared Function | 1 |
| BSD Camera | 720P AHD, Aviation Female Connector GX12, with Infrared Function | ≤4 |
• Others
| Name | Specification Model | Quantity |
|---|---|---|
| 4G, WiFi and GPS Three-in-One Antenna | 3m, Fakra Connector | 1 |
| Camera Extension Cable | 3M (Default) / 5M, with/without Bellows | ≤6 |
| SD Card | Standard Configuration: 128G SD Card | 1 |
| SIM Card/Internet of Things Card | Standard Card | 1 |
| Waterproof Cover Plate | 64x42x4 Plastic Cover Plate | 1 |
| Insulating Pad | 239x154x10 Plastic Pad | 1 |
| Display Screen | 7-inch, CVBS Display Screen (Optional) | 1 |
| Vehicle Control Wire Harness | Optional | 1 |
| Waterproof Cover | GX12 Waterproof Cover | ≤6 |
Frequently Asked Questions (PAA – People Also Ask)
What is an AI anti-collision system?
An AI anti-collision system uses sensors and machine learning to prevent forklift accidents by identifying obstacles, predicting collisions, and initiating alerts or automatic slowdowns.
How does the DMS camera detect fatigue?
The DMS uses infrared to monitor facial expressions and head position. Yawning or drooping eyes are flagged in real time.
Can this system work in low-light conditions?
Yes. The cameras are infrared-enabled with IP67 waterproofing and automatic exposure control.
Does it need internet to work?
While it uses 4G for remote updates and analytics, core detection works locally without constant connectivity.
Is it compatible with all forklifts?
The system is modular and designed with universal interfaces (GX12, CAN, RS232) making it compatible with most brands.
Final Thoughts: Smarter Safety Starts Here
Warehouse automation is booming, and with it, the need for smarter, more adaptive safety systems. The AI anti-collision system is not just a tech upgrade—it’s a necessity in modern logistics.
By combining real-time monitoring, predictive analytics, and vehicle control integration, this system ensures your operations remain safe, efficient, and future-ready.
Looking to upgrade your fleet with intelligent protection? Visit Teknect Global or contact sales@teknectglobal.com to request a demo and learn how AI can transform your warehouse safety strategy.
