ForkGuard AI

How it fits together

ForkGuard AI, part by part

Scroll or tap a part. Press “See the 3D CAD design” to watch the model, built from our CAD, light each part up and show how it connects.

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1. 01

   The whole ForkGuard AI

   A camera on the forklift guard spots people behind the truck and chimes the driver in under 300 ms; an impact sensor logs rack hits.

2. 02Brain

   Raspberry Pi Zero 2 W

   The brain: it runs the fg-vision, fg-imu, fg-io program

3. 

   03

   AI Camera (IMX500)

   Finds people behind the truck, on the sensor itself

   Raspberry Pi Zero 2 W · CSI-2 ribbon cable · Person boxes, no images

4. 

   04

   Impact sensor

   Feels hits at 400 Hz and wakes the logger

   Raspberry Pi Zero 2 W · I²C and GPIO 4 interrupt · Acceleration, impact wake

5. 05

   Cab LED bar

   Shows ready, check due or a red warning flash

   Raspberry Pi Zero 2 W · GPIO 18, level shifter · LED colour data

6. 06

   Cab piezo chime

   Gives a three-beep warning to the driver

   Raspberry Pi Zero 2 W · GPIO 13 PWM and MOSFET · 2 kHz chime drive

7. 07

   Cab mute button

   Driver presses to mute the chime for 10 s

   Raspberry Pi Zero 2 W · GPIO 27 pin · Button press

8. 08

   Truck power converter

   Turns truck battery power into 5 V for the unit

   Raspberry Pi Zero 2 W · 5 V on M12 cable · 5 V power

9. 09

   All connected

   7 key parts, one program, and your phone

The idea

One small kit on each forklift: impacts, reversing near misses and the daily pre-shift check, on one fleet dashboard

How the parts connect

ForkGuard AI, wired up

Every part, what links it to the brain, and how the data reaches your phone. A solid line is a cable; a dashed line is a radio link.

The program

What controls ForkGuard AI

camera.on('detections', boxes => {
  const people = tracker.update(boxes.filter(b => b.score >= 0.45));
  const bands = people.map(p => distanceBand(p.footPoint));   // danger, close, near
  const near = bands.some(b => b !== 'near');
  if (io.reverse && motion.moving && near) {
    if (++closeFrames >= 3 && !muted) io.chime(), io.led('red-flash');
  } else closeFrames = 0;
  if (near) db.insert('nearmiss', { band: closest(bands), zone });
});
imu.on('sample', a => {
  if (highPass(a) >= 3.0 && lasted(5)) db.insert('impact', peak());
});
setInterval(() => agent.flush(db, mqtt), 1000);   // when Wi-Fi is up

To your phone

How the data reaches ForkGuard dashboard and check app

Supervisor phone or laptop browser

1. Truck unit
2. Wi-Fi · MQTT/TLS
3. Site broker or cloud
4. Web app and SMS
5. Supervisor phone

Key specs

Targets for production units; they may change during development.

Pricing

Target pricing. Fitting by your forklift service provider or our partner network is quoted per site.

Indicative launch pricing in USD, excluding taxes and shipping. Final pricing is confirmed before any balance is charged.

1. 29 Oct 2026, 07:42LatestSmall warehouses with 5 to 40 mixed-brand forklifts find rack and door damage days later, never record near misses behind reversing trucks, and keep the OSHA daily pre-shift check on paper (OSHA 1910.178(q)(7), sources in DESIGN.md).

   • Drawn idea plan (idea.json): a small warehouse floor from above with the rack aisles, the pick-face walkway, dock doors, the charging bay and the shift office; pins for the camera unit on a reversing truck, its cab pod, the check tag on a truck in the charging bay and the manager’s dashboard
   • The product picture is now this drawn plan instead of the plain fallback card; drawn from the design notes, not the CAD
   • What the plan keeps from the market work: it sells evidence, not protection; the cab chime is a driver aid only and it never slows or stops the truck

   See it in 3DFull research and design

2. 27 Oct 2026, 07:52On a waste tipping floor three problems meet: lithium batteries hidden in loads start fires (UK waste firms reported 541 battery fires in the year to March 2026, waste360/ESA), loaders reversing among people on foot lead to big HSE fines (London Energy, £400,000 in 2025), and wrong items in a load cost money unless there is a photo to back-charge the customer (3rd Eye, WM). Our own three products for one hall cost $6,286 and $163 a month.

   • Combined into RecycleYard (https://iemilabs.com/products/recycleyard/); ForkGuard AI itself is unchanged

   See it in 3DFull research and design

3. 27 Oct 2026, 07:20A builders’ merchant, timber yard or garden centre lets customers drive in, park, queue at the will-call counter and walk among forklifts. WorkSafe NZ fined a timber yard after a forklift knocked a pack onto a customer and asked yards to control people on foot and show customers where to park. Today each job is a separate tool: about $950 a truck for an AI reversing camera, $35 a month per camera for plate reading, paid processing for traffic counts and $859-919 per people counter.

   • Combined into SafeYard (https://iemilabs.com/products/safeyard/); ForkGuard AI itself is unchanged

   See it in 3DFull research and design