This is a design project for a fully automated forklift from Toyota Material Handling. These work pieces are designed to work efficiently in a warehouse setting with the use of an autonomous navigation system to assist them in moving with precision. Distinctive features include load handling and balancing sensors to give these forklifts the capacity for autonomously lifting, unloading, and stabilizing, including going into recharge.While most of the developments in these fork lifters are somewhat impressive, they are coupled with a lot of challenges regarding safety and adaptability.

The capability of working alongside humans in a warehouse environment requires many features of safety. Currently, an electromagnetic brake drives the braking function, which also acts to drive the machine. An additional supportive braking unit for better safety and performance is necessary, and it forms the primary requirement for the project.The project approaches the design problem analytically by using principles of physics to determine the feasibility of a new braking design on fork wheels. A number of design tolerances will be considered to establish if it is feasible to utilize such a new system. The greatest problem lies in finding out a braking solution which, besides being technically feasible, can also be implemented within the constraints of existing machine design.

The project targets optimum braking performance, with consideration of environmental influences, as well as limitations to the operating system and safety.From this project, it is established that within the limitation of the design, a permanent magnet electromagnetic braking unit can be used. However, in this solution, the direct braking advantage is considerably less than what was expected. Therefore, the study goes the extent of exploring the feasibility of the development of a hybrid braking system, mechanical, and electromagnetic, for better performance output.These forklifts, developed by Toyota Material Handling belonging to the Toyota Group, have been aimed at solving problems in logistics and enhancing warehouse efficiency. 

However, these will have greater commercial value if adapted for smaller warehouses. This, therefore, is a design of the braking system to meet this requirement and ensure the forklift operates efficiently and safely in smaller spaces, making it an all-rounded tool for use in a wide range of environments.