– Many accidents are caused by incorrectly performed docking procedures, the wrong sequence of actions, or the lack of truck securing – points out Rüdiger Bierhenke, Head of Sales for Industrial Doors and Loading Technology at Hörmann.
The company has designed and launched a new security system that increases operational safety. The system consists of three main components: a distance sensor placed in the buffer, a wheel chock, a loading ramp with sensors, and a control unit. The applied solution is designed to facilitate vehicle docking, block dangerous actions, and warn employees of danger. The entire process is managed by an electronic control system designed and constructed by Hörmann, which controls the sequence of actions in every phase of the loading process.
Phase 1: Vehicle docking
Correct positioning of the truck is a prerequisite for safely placing the ramp on the loading platform. This means that the vehicle must stop at the appropriate distance from the ramp. This distance is measured using a sensor placed in the approach buffer (Hörmann Intelligent Buffer, HIB), which controls the traffic light signaling. A red traffic light informs the driver that the vehicle is in the optimal position. Such a solution guarantees that the loading ramp resting on the platform will not slip during loading. Furthermore, it prevents damage to the ramp and the vehicle due to inaccurate docking. Personnel working inside the hall can start loading at this point.
Phase 2: Opening the door and positioning the loading ramp
One of the most dangerous situations is a truck rolling away, for example, due to the failure to use a wheel chock. Hörmann Dock Control guarantees that the vehicle is secured before the industrial door is opened. The system blocks the opening of the door until the wheel chock is in place and a release signal is sent from the sensor. Inside, a “red” light flashes – now the sectional door can be opened. In this way, the system prevents situations where the door is opened prematurely, creating a risk of people and forklifts falling from a height.
Phase 3: Loading process
A message is sent to the electronic control system that the door has been fully opened. Only then can the loading ramp be lowered onto the truck platform and loading can begin. The system also warns of potential danger during loading and unloading. If, for example, the wheel chock moves due to vehicle movement, the traffic light inside the hall immediately switches to “red” and an audible warning signal sounds. In isolated cases, it may happen that a truck rolls away despite the wheel chock being in place. However, the distance sensor placed in the approach buffer immediately registers this change and sends a warning.
Phase 4: Releasing the vehicle
Just like during vehicle docking, Hörmann Dock Control also monitors the entire process in this phase: When the loading ramp is raised, the traffic light in the hall changes to “red”; after the door is closed, the external signaling flashes a “yellow” light, informing that the wheel chock has been removed. Finally, a “green” light signals to the driver that they can safely drive away.
The Dock Control system not only manages the entire loading process but also contributes to improving safety by preventing accidents and the associated costs.