Industrial Automation Solutions
Safety Without Compromise
Every HULCK Mover is engineered to protect people, goods and infrastructure — from laser obstacle detection to ATEX-certified explosion protection.
Seven Layers of Protection
Industrial transport involves heavy loads, confined spaces and mixed traffic with pedestrians and forklifts. A single safety feature is never enough. That is why every HULCK Mover can be equipped with up to seven independent safety systems — each addressing a different risk scenario.
Whether you operate in a clean-room pharmaceutical facility, an explosive-atmosphere chemical plant or a high-throughput automotive assembly line, the right combination of safety features turns the HULCK Mover into a zero-incident transport solution.
Laser Obstacle Detection
Scans the path ahead and stops the mover when an obstacle enters the safety zone
Typical Use Case:
Mixed traffic areas, automated routes
Anti-Collision Bumpers
Mechanical pressure-sensitive bumpers trigger an immediate stop on physical contact
Typical Use Case:
Narrow aisles, docking zones
Emergency Stop (E-Stop)
Hardwired mushroom-head buttons on the mover and remote for instant power cut
Typical Use Case:
All environments — mandatory baseline
Acoustic Warning Signal
Audible horn or beeper alerts pedestrians during travel and manoeuvres
Typical Use Case:
Warehouses, crossing zones
Visual Warning Lights
LED beacons and/or rotating lights indicate mover status and direction
Typical Use Case:
Low-visibility areas, multi-shift operations
ATEX-Certified Explosion Protection
Fully certified for operation in explosive atmospheres (gas/dust zones)
Typical Use Case:
Chemical, petrochemical, grain & food processing
Remote Control Operation
Wireless handheld or belt-pack controller keeps the operator at a safe distance
Typical Use Case:
Hazardous areas, precision positioning
See what the eye cannot — react before contact
Laser Obstacle Detection
HOW IT WORKS
LIDAR-based sensors continuously scan the area in front of (and optionally behind) the HULCK Mover. When an obstacle — a person, forklift or fallen pallet — enters the warning zone, the mover automatically reduces speed. If the obstacle enters the critical stop zone, the mover halts immediately.
Warning Zone
Configurable from 1 to 5 metres ahead of the mover. When an obstacle is detected in this zone, the mover decelerates to creep speed and activates an audible alert.
Stop Zone
Configurable from 0.3 to 2 metres. Immediate full stop. The mover does not resume until the zone is clear and the operator confirms.
Coverage Angle
Up to 270° scanning range depending on sensor configuration. Multiple sensors can provide full 360° coverage for omnidirectional travel.
When to Choose This
Required for any automated or semi-automated route where pedestrians or other vehicles may enter the mover’s path. Essential in mixed-traffic facilities and for movers that operate along fixed corridors.
Standards
Compliant with ISO 3691-4 (driverless industrial trucks) and EN ISO 13849 (safety of control systems for machinery), Performance Level d.
The last line of defence — instant stop on contact.
Anti-Collision Bumpers
HOW IT WORKS
Pressure-sensitive rubber bumpers are mounted along the leading edges of the HULCK Mover. The moment any part of the bumper strip is compressed — by a wall, rack, person or another vehicle — the mover cuts drive power and applies brakes within milliseconds.
Bumper Types
Standard soft-edge bumpers for general use. Heavy-duty foam bumpers for environments with frequent minor contact (e.g. docking stations). Custom profile bumpers for movers that operate in confined or irregularly shaped corridors.
Coverage
Full perimeter or partial coverage (front and rear only, or all four sides) depending on configuration and travel direction.
Reset
After a bumper activation event, the operator clears the obstruction and presses the reset button to resume travel. No tool or key required.
When to Choose
Standard on almost every HULCK Mover. Particularly important in narrow aisles, near docking bays, and anywhere the mover operates close to fixed structures or other equipment.
One press. Zero ambiguity.
Emergency Stop
HOW IT WORKS
Large, clearly visible mushroom-head push buttons are positioned on the mover body — typically on all four corners — and on the wireless remote control. Pressing any E-stop button immediately disconnects drive power, applies mechanical brakes and locks the mover in a safe state.
Placement
Minimum two E-stop buttons on the mover (front and rear). Four-corner placement available for large movers or those used in high-traffic areas. One additional E-stop on every remote control unit.
Reset Procedure
Twist-to-release mechanism ensures deliberate, conscious reset. The mover cannot restart until the E-stop is physically released and the operator presses the start button.
Wiring
Hardwired, fail-safe design. The E-stop circuit is independent of the mover’s software and PLC — it operates even if the control system fails.
When to Choose This
Mandatory on every HULCK Mover. It is the baseline safety feature and cannot be removed. The only configuration choice is the number and placement of buttons.
Heard before seen — every time.
Acoustic Warning Signal
HOW IT WORKS
An integrated horn or electronic beeper produces a clearly audible warning tone when the HULCK Mover is in motion, reversing, or approaching a crossing point. The sound level and pattern can be configured to suit the ambient noise of your facility.
Modes
Continuous tone during travel. Intermittent beep during reversing. A short alert burst when starting from standstill. Configurable activation triggers via PLC programming.
Volume
Adjustable from 75 dB to 105 dB to match your facility’s noise floor without causing unnecessary disturbance in quieter environments.
Frequency
Selectable tone frequency (typically 1,200 Hz or 2,400 Hz) to remain distinguishable from other industrial alarms.
When to Choose
Recommended for any environment where the mover shares space with pedestrians. Especially valuable at blind corners, doorway crossings and shift-change periods when foot traffic increases.
Status at a glance — from any angle.
Visual Warning Lights
HOW IT WORKS
LED beacons, rotating lights and optional LED strip lighting are mounted on the mover to communicate its operating status and travel direction to everyone in the vicinity.
Beacoun Colours
Green = ready/idle. Amber/orange = travelling. Red = fault or E-stop active. Blue = optional, used in specific industry protocols.
Directional Indicators
Optional LED arrow lights on the front and rear to signal travel direction, similar to vehicle turn indicators. Helpful in bidirectional travel scenarios.
Floor Projection
Optional blue or red spotlight projected onto the floor several metres ahead of the mover to warn pedestrians of the approaching vehicle — even around blind corners.
When to Choose This
Standard on most configurations. The floor-projection spotlight is especially popular in high-traffic warehouses and around corners where acoustic warnings alone may not be sufficient.
Safe operation where a single spark is unacceptable.
ATEX-Certified Explosion Protection
HOW IT WORKS
HULCK Movers configured for ATEX compliance are built with explosion-proof motors, sealed electrical enclosures, anti-static wheels and spark-free materials. Every component that could potentially generate an ignition source is eliminated or contained to a certified standard.
Certification Zones
Available for ATEX Zone 1 / Zone 21 (gas and dust environments where explosive atmospheres are likely to occur during normal operations) and Zone 2 / Zone 22 (where explosive atmospheres are not expected during normal operations but may occur for short periods).
Components
Ex-rated drive motors, explosion-proof junction boxes, intrinsically safe sensors, anti-static polyurethane or rubber wheels, and static-dissipative frame finishing.
Documentation
Full ATEX declaration of conformity, technical construction file and certification marking (Ex II 2G/2D or Ex II 3G/3D depending on zone classification).
When to Choose
Mandatory for chemical plants, refineries, grain handling facilities, paint shops, pharmaceutical production areas and any environment classified as ATEX Zone 1, 2, 21 or 22.
Full control — from a safe distance.
Remote Control Operation
HOW IT WORKS
A wireless handheld or belt-pack controller gives the operator full directional control of the HULCK Mover without being physically on or next to the vehicle. The operator can start, stop, steer and control speed from up to 100 metres line-of-sight.
Controller Types
Compact handheld unit with joystick and E-stop for basic forward/reverse/steer. Belt-pack controller with proportional joystick for precise multi-axis control (ideal for omnidirectional movers). Industrial-grade pendant with two-hand operation for heavy-duty applications.
Safety Features
Dead-man switch (the mover stops if the operator releases the control). Integrated E-stop on every controller. Frequency-hopping spread spectrum (FHSS) radio for interference-free operation in busy industrial RF environments.
Range
Up to 100 m line-of-sight. Effective range in complex indoor environments typically 30–60 m depending on building materials and interference.
When to Choose This
Standard on all HULCK Movers. The remote control keeps the operator at a safe distance from the load during transport and allows precise positioning during loading and unloading — especially useful with Lift Platform and Cassette Lift configurations.
Your Safety, Your Configuration
No two facilities are the same. A chemical plant with ATEX Zone 1 classification has very different requirements from an automotive assembly hall. That is why every safety feature on the HULCK Mover is modular and independently configurable.
Here are three common safety packages our clients choose:
Package 1
Standard Industrial
Anti-Collision Bumpers (full perimeter)
Acoustic Warning Signal
Visual Warning Lights (amber beacon)
Remote Control
Suitable for: Warehouses, production halls, logistics centres.
Package 2
High-Traffic Facility
Laser Obstacle Detection (front + rear, 270°)
Floor-Projection Spotlight
Directional LED Indicators
Suitable for: Mixed pedestrian/vehicle traffic, multi-shift operations, automated routes.
Package 3
Hazardous Environment (ATEX)
Full ATEX Zone 1/21 certification
Explosion-proof motors and sealed electronics
Anti-static wheels
Laser Obstacle Detection (ATEX-rated sensors)
Suitable for: Chemical plants, refineries, grain handling, paint shops.
Built to the Highest Standards
Every HULCK Mover is designed, manufactured and tested in compliance with European and international safety standards. Our safety systems are not afterthoughts — they are engineered into the mover from the initial design phase.
CE Marking
Conformity with all applicable EU directives for machinery safety
ISO 3691-4
Safety requirements for driverless industrial trucks and their systems
EN ISO 13849
Safety of control systems for machinery — Performance Level d
ATEX Directive
2014/34/EU
Equipment for use in explosive atmospheres
EMC Directive
2014/30/EU
Electromagnetic compatibility for industrial environments
Machinery Directive 2006/42/EC
Essential health and safety requirements for machinery
Not Sure Which Safety Package You Need?
Our engineers analyse your facility layout, traffic patterns and regulatory requirements — then recommend the exact safety configuration for your HULCK Mover. No over-specification, no unnecessary cost.