IPAS - Pedestrian and forklift warning system

How does the IPAS warning system work?

IPAS is based on wireless communication between transponders mounted on vehicles, industrial machinery, and employee clothing or personal protective equipment (helmets, lanyards, belts, vests, etc.). Utilizing advanced Ultra-Wideband (UWB) technology, these devices continuously monitor each other's location, precisely measuring the distance between them in real time. This forms a highly responsive pedestrian warning and collision avoidance system that enhances safety in shared workspaces, protects forklift operators and pedestrians, and mitigates risks in high-traffic zones.

When a vehicle approaches a pedestrian or another object at a hazardous distance, the system immediately triggers an alert. Supported by visual, audible, and vibration signals, this automated proximity alert ensures approaching equipment is instantly noticed, even in loud industrial environments or restricted-visibility areas. Consequently, collision risks around forklifts, trucks, and heavy equipment are drastically minimized.

IPAS supports multi-directional communication across a variety of operational setups:

• Vehicle-to-vehicle (Trolley-to-trolley) communication: Enables moving vehicles and material handling carts to detect one another. Crucial in congested warehouses or manufacturing halls, this proactive collision avoidance system helps operators maintain safe distances and maintains smooth traffic flow.
• Vehicle-to-pedestrian (Trolley-to-pedestrian) communication: Detects wearable transponders on pedestrian workers. When a vehicle enters a hazardous zone, both the operator and the pedestrian receive instantaneous alerts via sound, flashing lights, or vibration, allowing for quick evasive action.
• Zone warning: Safeguards high-risk blind spots, blind corners, and busy intersections. Clearly defined safety zones allow managers to control traffic, boost hazard awareness, and enforce facility safety protocols.
• Intersections & crossings: Optimizes intersection safety and priority management where vehicle and pedestrian routes cross, virtually eliminating blind-spot accidents.
• EOD (External Output Device) integration: Transmits actionable signals to execute automated safety events, such as slowing down a forklift in a specific zone, opening an automated gate, or triggering external LED sign projectors and alarms. It seamlessly integrates with existing safety networks, CCTV systems, RFID setups, or charging stations.

What does the IPAS pedestrian and vehicle warning system consist of?

The IPAS system comprises several modular components that work in unison to deliver comprehensive site protection. The compact, lightweight wearable transponders easily attach to hard hats, safety vests, or belts for comfortable daily use.

Engineered with high technical specifications, IPAS provides distance measurements accurate to within 10 centimeters across ranges from 10 to 30 meters, speed-adaptive detection zones, and three distinct alert modes (audible tone, physical vibration, and flashing light). This combination of accurate proximity monitoring and multi-sensory warnings delivers robust protection for forklifts, trucks, and personnel operating in dense material handling environments.

Vehicle kit

Pedestrian kit

Zone set

Zone kit + warning sign projector

IPAS warning system - implementation benefits

Implementing IPAS in an industrial facility delivers immediate safety and operational gains. First and foremost, management gains full confidence that pedestrians and equipment operators (forklifts, excavators, wheel loaders, tractors, etc.) are safeguarded against unpredictable hazards. Automated real-time warnings prevent accidents, fostering a safer, lower-stress work environment for the entire team. For the business, this reduces equipment damage, lowers insurance liabilities, and minimizes costly operational downtime.

Beyond collision prevention, IPAS offers multi-functional utility across other plant operations:

• Proximity and distance management: Built-in transponder sensors can track distance between individual personnel. If workers breach a preconfigured safety boundary (adjustable from 1 to 5 meters), wearable units sound a warning tone and vibrate, reinforcing physical distancing and safety rules.
• Automated access control: Zone antennas connect directly to access control devices, such as automated gates or turnstiles. Gates can be set to open only when an authorized active transponder approaches, controlling room occupancy and preventing overcrowding.
• Automatic speed zoning: By connecting zone antennas to vehicle control systems, forklifts automatically slow down to a pre-set speed limit when entering critical or high-density pedestrian zones. Speed reduction in hazardous areas drastically decreases collision severity and frequency, protecting both personnel and site infrastructure.

The cost of implementing an IPAS warning system

Ensuring safety across logistics centers, factories, construction sites, mines, and ports is critical. IPAS stands as one of the most advanced proximity protection solutions available on the European market, combining ultra-wideband technology with versatile hardware integration. Because system requirements vary depending on facility architecture, traffic patterns, vehicle counts, and pedestrian volume, pricing is customized per project. Contact our specialists today to receive a personalized quote and implementation strategy tailored to your facility.