Retrofitting a Standard Forklift for Remote and Semi-Autonomous Operation

The challenge

A warehouse automation startup wanted existing forklifts to be driven remotely and then, step by step, operate on their own, without customers replacing their fleets. That called for a retrofit kit that could take control of a standard forklift, show a remote operator what the machine sees with very little delay, and stay safe around people and racking.

What we did

We began with a proof of concept in a simulated warehouse to test remote-operation workflows before building hardware. We then designed electronics that work alongside the forklift's own controls, with distinct manual, remote and autonomous modes, and multi-camera video streaming to a browser-based operator station. Independent safeguards, including watchdogs, emergency stops and safety-rated sensing, make the machine fail safe.

On top of that we developed the robotics software stack, built on ROS 2, and perception for detecting pallets, the groundwork for autonomous pick-up and put-down.

The result

The startup gained a working teleoperated forklift and moved into field trials of autonomous pallet handling, with the hardware designs, software and documentation needed to keep developing the product.

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