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The Madoors USA Loading Dock Vehicle Restraint Smart Chock is a patented, handheld electronic rechargeable steel tire wedge system providing intelligent automated vehicle restraint at loading docks — preventing loading dock accidents including forklifts driving off the edge of the dock, forklift entry before the vehicle is secured, and premature vehicle departure during loading operations. The completely steel structure with IP67 PNP limit switches detects the truck tire, communicates with the remote PLC control panel, controls traffic light red/green signals and audible alerts, and interlocks the loading door, dock leveler, and loading bellows to prevent operation unless the tire wedge is correctly in place and confirmed locked. Rechargeable and cable-free for complete portability, manufactured in electrostatic powder paint, stainless steel, and hot-dip galvanized options, compatible with all vehicle types in all weather conditions, and carrying a 2-year warranty, the Madoors USA Smart Chock is the ultimate workplace health and safety solution for any loading dock.
TECHNICAL SPECIFICATIONS
The Madoors USA Smart Chock is manufactured from completely steel construction — robust, non-bending, non-breaking steel body that withstands the vehicle tire weight loading and the physical handling of daily portable deployment throughout the full service life. The steel body is finished in electrostatic powder paint as standard, with stainless steel and hot-dip galvanized options for corrosive and demanding outdoor installation environments.
The IP67-rated PNP limit switches embedded within the chock body detect the truck tire when the chock is correctly placed under the tire — IP67 confirms dust-tight and temporary water immersion protection for the sensing electronics, directly ensuring reliable sensor function in all outdoor and dock floor conditions including rain, wash-down water, and mud. The IP67 sensor rating is the critical specification for a device that is placed directly on a dock floor under a truck tire in all weather conditions.
The rechargeable battery system eliminates the cable that conventional hardwired chock systems require — the chock is taken from the charging unit, deployed at the truck tire position, and operates wirelessly through the full loading cycle on battery power. Cable elimination removes the cable breakage failure mode, the trip hazard of cables across the dock approach, and the service call requirement for cable damage repair. The rechargeable system is returned to the charging unit after each loading cycle for battery restoration.
The PLC unit and software manage the complete dock safety interlock logic — the loading door cannot be opened, the forklift cannot be allowed on the dock, the dock leveler cannot be activated, and the loading bellows cannot operate unless the Smart Chock confirms tire detection and the traffic light is red. If any safety condition is violated — premature chock removal, loading door opened before vehicle is secure, or chock removed before loading completion is confirmed — the red light flashes continuously and the audible signal sounds continuously until the condition is corrected.
The remote control panel receives the tire detection signal from the chock, displays the dock status, and provides the operator with the traffic light control interface. Red traffic light and 10-second audible signal on tire lock confirmation — indicating to both dock workers and the driver that the vehicle is secured and loading operations may commence. Green light and 10-second audible signal after loading completion and chock removal — authorizing the driver to depart.
KEY FEATURES
Patented IP67 Tire Detection — Confirmed Vehicle Lock Communication
The IP67 PNP limit switches that detect the truck tire under the chock and transmit confirmation to the remote PLC panel provide the verified vehicle lock communication that eliminates the assumption-based dock operation that causes accidents — the dock system does not proceed to loading readiness based on visual confirmation or operator assumption, but only on confirmed electronic sensor detection that the chock is under the tire. This electronic confirmation directly eliminates the most common cause of loading dock accidents — commencing loading before the vehicle is confirmed secure.
Complete Dock Interlock — Door, Forklift, Leveler & Bellows
The PLC interlock that prevents loading door opening, forklift dock access, dock leveler activation, and loading bellows operation unless the Smart Chock confirms tire lock provides the complete dock safety sequence enforcement that prevents every category of loading dock accident — no single dock operation can proceed out of safe sequence, and no individual operator error can bypass the safety interlock. This complete interlock architecture is the definition of a true workplace safety system — the physical dock equipment cannot be operated in an unsafe sequence regardless of operator action.
Cable-Free Rechargeable — No Cable Failure Risk
The cable elimination through rechargeable battery operation removes the cable breakage failure mode that is the most common operational failure of hardwired chock systems — a broken cable renders the chock system inoperative and requires a service call that takes the dock out of service. The rechargeable system has no cable to break, no cable to create trip hazards, and no cable-related service call requirement. This cable-free reliability directly maximizes dock operational availability and eliminates the maintenance downtime associated with cable damage repair.
Premature Removal Alert — Continuous Red Flash & Audible Signal
The continuous red light flashing and continuous audible signal triggered by premature chock removal before loading completion — before the loading door is closed, before the forklift has left the dock, and before the leveler and bellows are retracted — provides the immediate, unmissable alert required to stop an unsafe departure before the vehicle moves. The continuous signal cannot be ignored or missed — it continues until the chock is replaced under the tire, directly preventing the accident scenario where the driver departs before dock operations are completed.
Driver & Dock Worker Dual Audience Communication
The traffic light and audible signal system communicates simultaneously to both the dock worker inside the warehouse and the driver in the truck cab — the driver-targeted lighting system ensures that the driver sees the red secured and green departure signals directly, eliminating the communication gap between dock worker and driver that is the root cause of many dock departure accidents. This dual audience communication design directly addresses the human factors engineering requirement for dock safety — both parties to the dock operation must receive the same safety status information simultaneously.
Lightweight All-Steel Construction — All Vehicle & Weather Compatibility
The lightweight all-steel construction with ultrasonic sensor provides the combination of portability required for handheld daily deployment and the structural robustness required for placement under truck tires of all vehicle types in all weather conditions. The lightweight specification allows single-operator placement and retrieval without effort, maintaining the practical usability of the chock across all dock staff capabilities. The all-weather ultrasonic sensor operation extends reliable detection capability to rain, snow, ice, and all dock floor conditions.
Little Maintenance — Maximum Dock Productivity
The innovative safety solution that requires little maintenance directly contributes to the loading dock's productive utilization — minimal maintenance means minimal downtime for maintenance events and minimal maintenance cost over the operational service life. The rechargeable battery system, IP67 protected sensors, and steel construction all contribute to the low-maintenance characteristic of the Smart Chock system.
Accident Prevention Before Occurrence — Safety System Philosophy
The Madoors USA Smart Chock is specifically designed to prevent potential workplace accidents before they occur — the system alerts dock workers and drivers of an accident condition before the accident happens rather than responding after. This prevention philosophy is the essential distinction between a true safety system and a reactive incident response system — the Smart Chock stops the unsafe condition from reaching the accident outcome, directly reducing loading dock injuries and the associated liability, insurance, and productivity costs.
SMART CHOCK OPERATIONAL SEQUENCE
Step 1 — Retrieve from Charging Unit
The dock operator retrieves the fully charged Smart Chock from the charging unit. The chock is confirmed charged and operational.
Step 2 — Placement Under Truck Tire
The chock is placed under the specified truck tire at the dock position. The IP67 PNP limit switches detect the tire contact with the chock body.
Step 3 — Tire Lock Signal Transmission
The chock transmits tire detection confirmation to the remote PLC control panel. The PLC software confirms secure tire lock status.
Step 4 — Red Traffic Light & 10-Second Audible Warning
The traffic light turns red and a 10-second audible warning signals to dock workers and driver — the vehicle is secured and loading operations may commence. The warning confirms the wedge is under the tire.
Step 5 — Loading Door, Leveler & Bellows Activation Authorization
The PLC software authorizes loading door opening, dock leveler activation, and bellows operation. The forklift is authorized to access the loading dock. Loading operations commence.
Step 6 — Loading Completion Confirmation
Loading is completed. The loading ramp returns to the stop position or the forklift exits and the door is closed. The dock is confirmed cleared for vehicle departure.
Step 7 — Chock Removal
The tire wedge is pulled from under the vehicle tire. The tire is released.
Step 8 — Green Light & 10-Second Departure Signal
The green traffic light activates and a 10-second audible signal confirms vehicle departure authorization. The driver is signaled that departure is safe.
Step 9 — Premature Removal Response (Safety Override)
If the chock is removed before loading door closure, forklift dock exit, and leveler/bellows retraction are confirmed — the red light flashes continuously and the audible signal sounds continuously until the chock is replaced under the tire.
Step 10 — Chock Return to Charging Unit
The chock is returned to the charging unit for battery restoration, ready for the next dock loading cycle.
ASSEMBLY & INSTALLATION SEQUENCE
Dock Assessment & PLC System Configuration
Dock position count, loading door interlock interface, dock leveler connection, bellows interface, traffic light mounting positions, remote control panel position, charging unit location, and power supply are confirmed.
Traffic Light Installation
Driver-facing external traffic light and dock worker-facing internal traffic light are installed at the confirmed positions visible to both the driver cab and the dock interior.
Remote PLC Control Panel Installation
The PLC control panel and software are installed at the dock control position. Interfaces with loading door, dock leveler, bellows, and traffic lights are connected and programmed.
Charging Unit Installation
The Smart Chock charging unit is installed at the dock operator position. Charging function and charge status indication are tested.
Smart Chock Sensor & Communication Testing
IP67 PNP limit switch tire detection, wireless transmission to PLC, traffic light red activation, audible signal, dock interlock authorization sequence, and premature removal continuous alarm are all tested through the complete operational sequence.
2-Year Warranty Documentation & Handover
Complete Smart Chock system operational testing across the full dock cycle sequence is conducted. 2-year warranty documentation and installation records are compiled into the project handover package.
DEPLOYMENT SCENARIOS & USE CASES
Madoors USA Loading Dock Vehicle Restraint Smart Chocks are specified for any loading dock requiring intelligent electronic tire wedge vehicle restraint with dock operation interlock.