Smart Shelf Safety Monitoring System Solution

Prevent Shelf Collapse, Ensure Personnel and Cargo Safety

• Structural Stability Monitoring: Shelf tilting may result from foundation settlement, overloading, forklift collisions, or long-term uneven stress. If not addressed promptly, it may lead to collapse accidents.
• Early Warning: Slight tilting is hard to detect with the naked eye, but through tilt sensors or regular inspections, potential hazards can be identified in advance to avoid catastrophic consequences.

Avoid Cargo Sliding or Damage

• Center of Gravity Balance: Shelf tilting causes cargo center of gravity to shift, especially for high-level shelves or heavy goods, which can easily lead to sliding or tipping, causing cargo damage or even personnel injury.
• Special Cargo Protection: Precision instruments, fragile items (e.g., glass, electronics) have higher requirements for shelf levelness; even slight tilting may cause packaging damage or product breakage.

Adapt to Automated Warehouse Systems (e.g., AGV/Stacker Crane)

• Precise Positioning Requirement: Automated warehouses rely on standard shelf arrangement; if tilting exceeds the allowable range (e.g., ±0.5°), it may cause stacker crane picking failures or collisions.
• System Linkage: Real-time tilt data can be fed back to the Warehouse Management System (WMS) to automatically adjust robot paths or pause operations in hazardous areas.

Comply with Safety Regulations and Industry Standards

• Legal Requirements: Regulations such as OSHA (Occupational Safety and Health Administration, USA) and GB/T Code for the Use of Storage Shelves require regular inspection of shelf structures; if tilt exceeds limits, shelves must be taken out of service for repair.
• Insurance and Liability: Some insurers require enterprises to install tilt monitoring devices; otherwise, claims may be denied after an accident.

Reduce Maintenance Costs, Extend Shelf Lifespan

• Preventive Maintenance: By monitoring tilt changes, determine whether to reinforce footings, adjust beams, or replace damaged components — preventing minor issues from escalating into major repairs.
• Reduce Downtime Loss: Sudden collapse can halt warehouse operations; regular inspections maximize operational continuity.

Total Function of System

Tilt detection requires a complete system to ensure data usability. Our company has developed a full set of tilt monitoring system, which consists of front-end sensor inclinometers, wireless transmission, alarm terminals, mobile apps, and cloud platforms. Below, we will introduce wireless transmission, alarm terminals, cloud platforms, and tilt sensors respectively. The following is the block diagram of this system:

The overall system is used as follows: An inclinometer is installed on each shelf and can be powered by battery or continuous power supply. Transmission options include LoRa, LoRaWAN, or Wi-Fi. A display terminal is placed in front of each group of shelves to show the tilt level of that particular shelf group.

Wireless Transmission

This system employs three types of wireless transmission: LoRa/LoRaWAN, Wi-Fi, and CAT1 (4G). Each is tailored to a specific usage environment.

• LoRa/LoRaWAN​ is suited for large-scale localized environments with high demands on sensor power efficiency, long transmission range, and centralized management — such as logistics warehouse shelving systems.
• Wi-Fi​ is appropriate for environments where sensor power consumption is not critical and Wi-Fi coverage is available.
• CAT1 (4G)​ is designed for widely dispersed, large-scale environments — such as telecommunication towers or structurally unsafe buildings.

Cloud Platform

Core Functions

Multi-Protocol Device Access

• Supports tilt sensors接入 via multiple communication protocols including Wi-Fi, LoRa/LoRaWAN, and Cat1
• Automatically identifies device type and communication protocol
• Provides standardized device access interfaces

Real-Time Data Monitoring

• Receives and parses tilt angle data (X/Y/Z axes) reported by sensors
• Real-time display of device status and tilt data
• Offers 2D/3D visualization interface
• Supports historical data query and playback

Intelligent Alarm Management

• Configurable multi-level tilt alarm thresholds
• Supports multiple notification methods: SMS, email, app push, etc.
• Hierarchical alarm information processing mechanism
• Alarm record storage and retrieval

Full Lifecycle Device Management

• Device registration, configuration, and grouping management
• Device status monitoring (online/offline)
• Remote parameter configuration and firmware upgrade
• Device maintenance record management

Data Analysis & Reporting

• Tilt trend analysis
• Equipment health status assessment
• Custom report generation
• Data export functionality

Inclination Sensor

Alarm Terminal