Design and development of a low-cost, eco-friendly forklift for sustainable logistics management
The U.S. Occupational Safety and Health Administration’s (OSHA) most recent estimates show that between 35,000 and 62,000 injuries occur every year due to forklift-related accidents. According to the National Safety Council (NSC) data, approximately 78 fatalities are reported every year. Moreover, m...
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Frontiers Media S.A.
2025-01-01
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| Series: | Frontiers in Built Environment |
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| Online Access: | https://www.frontiersin.org/articles/10.3389/fbuil.2024.1506495/full |
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| author | Asif Jalal Muhammad Farooq Izza Anwer Nasir Hayat Adeel Munir Imran Zahid Noreen Sher Akbar M. Hamza M. Nouman Fahid Riaz |
| author_facet | Asif Jalal Muhammad Farooq Izza Anwer Nasir Hayat Adeel Munir Imran Zahid Noreen Sher Akbar M. Hamza M. Nouman Fahid Riaz |
| author_sort | Asif Jalal |
| collection | DOAJ |
| description | The U.S. Occupational Safety and Health Administration’s (OSHA) most recent estimates show that between 35,000 and 62,000 injuries occur every year due to forklift-related accidents. According to the National Safety Council (NSC) data, approximately 78 fatalities are reported every year. Moreover, manual loading and unloading of heavy items is time-consuming and poses significant risks to workers in small and crowded warehouses. To address these safety and efficiency concerns cost-effectively, an automated robotic forklift prototype was developed. The key features of this industrial robot include full rotational mobility with a zero-degree turning radius, which reduces the time and space required to turn around corners. It can be operated remotely via a mobile phone using Bluetooth or wi-fi. The motion control system, based on the ESP-32 microcontroller, significantly enhances its operational efficiency compared to manual operation. This study evaluates the performance of the robotic forklift prototype, cost-effectiveness, with loading and unloading capabilities as effective solutions to the challenges faced by workers. Additionally, structural analysis using Ansys confirmed that the design can safely withstand forces 60% greater than the intended design load of 50 N. Furthermore, the maximum stress experienced by the fork is 67% below the material yield strength, further demonstrating robustness and reliability. The integration of advanced technology and Eco-friendly design positions this forklift as a viable and sustainable option for improving material handling in various industrial sectors. |
| format | Article |
| id | doaj-art-d67e59e8c1324f0799a934b093000003 |
| institution | Kabale University |
| issn | 2297-3362 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Frontiers Media S.A. |
| record_format | Article |
| series | Frontiers in Built Environment |
| spelling | doaj-art-d67e59e8c1324f0799a934b0930000032025-01-06T06:59:13ZengFrontiers Media S.A.Frontiers in Built Environment2297-33622025-01-011010.3389/fbuil.2024.15064951506495Design and development of a low-cost, eco-friendly forklift for sustainable logistics managementAsif Jalal0Muhammad Farooq1Izza Anwer2Nasir Hayat3Adeel Munir4Imran Zahid5Noreen Sher Akbar6M. Hamza7M. Nouman8Fahid Riaz9Department of Mechanical Engineering, University of Engineering and Technology Lahore, Lahore, PakistanDepartment of Mechanical Engineering, College of Engineering, Prince Mohammad Bin Fahd University, Al-Khobar, Saudi ArabiaDepartment of Transportation Engineering and Management, University of Engineering and Technology, Lahore, PakistanDepartment of Mechanical Engineering, University of Engineering and Technology Lahore, Lahore, PakistanDepartment of Mechanical Engineering, University of Engineering and Technology Lahore, Lahore, PakistanDepartment of Mechanical Engineering and Technology, GCU Faisalabad, Faisalabad, PakistanDepartment of Mechanical Engineering, College of Engineering, Prince Mohammad Bin Fahd University, Al-Khobar, Saudi ArabiaDepartment of Mechanical Engineering, University of Engineering and Technology Lahore, Lahore, PakistanDepartment of Mechanical Engineering, University of Engineering and Technology Lahore, Lahore, PakistanDepartment of Mechanical Engineering, Abu Dhabi University, Abu Dhabi, United Arab EmiratesThe U.S. Occupational Safety and Health Administration’s (OSHA) most recent estimates show that between 35,000 and 62,000 injuries occur every year due to forklift-related accidents. According to the National Safety Council (NSC) data, approximately 78 fatalities are reported every year. Moreover, manual loading and unloading of heavy items is time-consuming and poses significant risks to workers in small and crowded warehouses. To address these safety and efficiency concerns cost-effectively, an automated robotic forklift prototype was developed. The key features of this industrial robot include full rotational mobility with a zero-degree turning radius, which reduces the time and space required to turn around corners. It can be operated remotely via a mobile phone using Bluetooth or wi-fi. The motion control system, based on the ESP-32 microcontroller, significantly enhances its operational efficiency compared to manual operation. This study evaluates the performance of the robotic forklift prototype, cost-effectiveness, with loading and unloading capabilities as effective solutions to the challenges faced by workers. Additionally, structural analysis using Ansys confirmed that the design can safely withstand forces 60% greater than the intended design load of 50 N. Furthermore, the maximum stress experienced by the fork is 67% below the material yield strength, further demonstrating robustness and reliability. The integration of advanced technology and Eco-friendly design positions this forklift as a viable and sustainable option for improving material handling in various industrial sectors.https://www.frontiersin.org/articles/10.3389/fbuil.2024.1506495/fullbattery-operated forkliftautonomous forklift360-degree rotating vehiclezerodegree turning radiusDC gear motorESP-32 motion control System |
| spellingShingle | Asif Jalal Muhammad Farooq Izza Anwer Nasir Hayat Adeel Munir Imran Zahid Noreen Sher Akbar M. Hamza M. Nouman Fahid Riaz Design and development of a low-cost, eco-friendly forklift for sustainable logistics management Frontiers in Built Environment battery-operated forklift autonomous forklift 360-degree rotating vehicle zerodegree turning radius DC gear motor ESP-32 motion control System |
| title | Design and development of a low-cost, eco-friendly forklift for sustainable logistics management |
| title_full | Design and development of a low-cost, eco-friendly forklift for sustainable logistics management |
| title_fullStr | Design and development of a low-cost, eco-friendly forklift for sustainable logistics management |
| title_full_unstemmed | Design and development of a low-cost, eco-friendly forklift for sustainable logistics management |
| title_short | Design and development of a low-cost, eco-friendly forklift for sustainable logistics management |
| title_sort | design and development of a low cost eco friendly forklift for sustainable logistics management |
| topic | battery-operated forklift autonomous forklift 360-degree rotating vehicle zerodegree turning radius DC gear motor ESP-32 motion control System |
| url | https://www.frontiersin.org/articles/10.3389/fbuil.2024.1506495/full |
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