Safety technologies in the use of agricultural machinery
The agricultural sector continues to experience a high rate of fatal accidents, with tractor overturning being the leading cause. To address these risks, alongside regulatory advancements, increasingly effective safety solutions have emerged: from the passive protection provided by ROPS to active prevention systems that rely on driving assistance technologies. Furthermore, fully autonomous machinery managed by artificial intelligence and operating without an onboard operator is starting to appear, aiming to eliminate risks for operators completely
Alongside the construction sector, agriculture sadly continues to hold the record for fatal workplace injuries. One of the primary causes is tractor overturning, historically the most severe event for agricultural operators, with an average of approximately 115 fatalities reported each year in Italy. Accidents in agriculture stem from a complex phenomenon related to structural factors of machinery (which often have a high center of gravity and substantial engine torque), harsh operational conditions (such as sloping terrains and heavy or irregular loads), as well as improper driving behaviors.
The mechanization evolution has undoubtedly enhanced productivity; however, it has also introduced new risks, particularly with the increased use of more powerful and complex machinery. Therefore, it is crucial to enhance safety levels, particularly in environments where outdated machines remain in service or where training is inadequate.
Over recent decades, the approach to safety has evolved through two complementary strategies. Passive safety focuses on mitigating the consequences of accidents, while active safety aims to prevent them by addressing their causes. Obviously, these two strategies should not be viewed in isolation; rather, they can effectively integrate to maximize safety levels. In fact, these approaches have been embedded in international regulations and the design choices of manufacturers for some time, forming the basis for a new generation of tractors—and, more broadly, agricultural machinery—that can significantly reduce risk.
Passive safety: Limiting damage in case of overturning. The primary device implemented globally to enhance safety is the ROPS (Rollover Protective Structure), designed to maintain a specific "survival volume" in the event of a rollover. Made of steel profiles, these structures are installed in the operator's area, either independently or integrated into the cabin itself. To ensure their suitability, ROPS are subjected to mandatory testing for certification according to EU, ISO, or OECD standards. These tests encompass both static and dynamic evaluations that verify their resistance during overturning. However, ROPS alone is insufficient: without a securely fastened seatbelt, the operator can be thrown from the tractor during an overturn, nullifying the protection provided by the structure. In Italy, the requirement for ROPS installation has been in effect for over 50 years, but older tractors, still in use today, often feature outdated structures prone to corrosion and damage. Furthermore, for several reasons, the actual use of seatbelts is frequently ignored. To counter this significant issue, "binding" systems are being researched to prevent vehicle start-up if the seatbelt is not fastened properly. These technologies replicate successful solutions already in use in the automotive sector, however, they are adapted to the unique challenges of the agricultural environment, which presents more difficult climatic and operational conditions. Such technologies include the installation of proximity sensors, pressure switches in seat cushions, and gyroscopes to verify the physical presence of the operator, often combined with magnetic or tension sensors in the seatbelt buckle to ensure proper fastening. At a more advanced level, considerations are being given to incorporating systems with artificial vision modules that employ cameras operated by facial and positional recognition algorithms to verify whether the operator is seated correctly.
In the specific segment of orchard and vineyard tractors where collapsible ROPS are often left in the lowered position, researchers are exploring solutions to automate or assist in restoring protection before use. Some systems, tested since 2008, utilize tri-axial accelerometers and digital inclinometers to detect imminent risk situations (such as significant slopes or abnormal lateral accelerations) and activate a servo-assisted mechanism (electro-hydraulic and electric) that automatically and quickly returns the roll bar to a vertical safety position. These devices can also be controlled by electronic control units (ECUs) that integrate operational logic based on configurable thresholds for incline, speed, and operator position, allowing for manual deactivation only under specific safety conditions (e.g., when the engine is off). Nonetheless, the prevalence of these solutions remains quite limited, mainly due to high retrofit costs on existing equipment, a lack of willingness from operators to incur new expenses, and the current absence of stringent regulatory requirements regarding their use. The future aim is to incorporate these "intelligent" systems at the design phase of new tractor models, with user-friendly interfaces designed to guide operators and promote safe practices without compromising agricultural efficiency.
Active safety: Preventing accidents before they happen. Active safety in modern agricultural vehicles encompasses a collection of solutions engineered to prevent accidents by intervening prior to the onset of dangerous situations. With advancements in technology, it is now possible to manage self-propelled machinery more accurately and safely, even under challenging conditions such as muddy terrain, steep slopes, or uneven surfaces. Notable innovations include intelligent braking systems, such as ABS, (which have been adapted to accommodate the specific needs of agricultural machinery), preventing wheel lock during braking and enabling the vehicle to maintain its course even during emergency maneuvers.
Together with these features, traction and stability control systems regulate the power supplied to the wheels in real time, reducing the risk of skidding and loss of traction that could lead to an overturn. Such solutions are designed to assist operators in maintaining control of their machinery (and any connected implements) even in precarious situations. A significant advancement in active safety is the integration of advanced sensors and environmental perception technologies, which transform tractors into semi-autonomous platforms capable of monitoring their surroundings and proactively addressing potential risks.
Technologies such as millimeter-wave radar, Light Detection and Ranging (LiDAR), multispectral cameras, and GNSS modules with Real-Time Kinematic (RTK) correction enable precise, three-dimensional awareness of the operational environment. These systems, which have been implemented in models like John Deere's 8R and 5ML, generate digital maps of the field in real time, identify static (such as trees, posts, and ditches) and dynamic obstacles (like animals, people, and other vehicles), calculate predictive trajectories, and utilize collision avoidance algorithms to execute automatic maneuvers, including emergency braking, controlled steering, or speed reduction. Additionally, New Holland’s PLM Intelligence platform offers features such as 360-degree vision, obstacle detection, and continuous tracking of the operator.
To support the driver, modern cabin designs include advanced human-machine interfaces with high-visibility touch displays, LED panels, multi-tonal alerts, and ergonomic controls integrated into armrests or steering wheels. These tools are developed according to cognitive ergonomics principles, optimizing information readability, simplifying decision-making, and reducing reaction times in critical situations (such as when incline thresholds are exceeded or significant skidding occurs). Some manufacturers are even exploring biometric monitoring systems for operators, incorporating capacitive sensors within seats, facial and eye recognition cameras, or wearable Bluetooth-connected devices. Monitored parameters include fatigue (such as "microsleeps" or improper postures), inattentiveness (loss of visual focus on the path), and physiological changes (like heart rate and body temperature). If certain risk thresholds are crossed, the system can issue visual or auditory alerts and, in some cases, slow down or stop the vehicle in a controlled manner.
Ultimately, assisted and autonomous driving represent the pinnacle of active safety advancements. By integrating RTK GPS with predictive control algorithms, tractors can execute operations with centimeter-level accuracy, maintain virtual lanes, adjust speed based on slope or soil conditions, and automatically identify ends of rows for turning maneuvers. Systems such as Fendt's VarioGuide facilitate assisted automatic driving and include radar for braking support. These technologies are interconnected with IoT platforms, which relay operational data (such as fuel consumption, telemetry, and diagnostic errors) to remote dashboards, enabling real-time monitoring, predictive maintenance, and automatic requests for technical assistance in case of anomalies. Despite the increasing availability of advanced technologies, the importance of operator training should not be overlooked. Familiarity with safety devices, proficiency in their proper use, and continuous risk awareness are essential for ensuring a genuinely safe working environment. Only by merging innovative technology with a robust safety culture can we significantly reduce the incidence of accidents in agriculture.
Towards operator-free safety. Robotics, artificial intelligence, advanced sensors, and real-time connectivity are deeply transforming the design and use of agricultural machinery. Transitioning from an active driver, the operator is gradually redefining their role as an external supervisor, with the goal of drastically reducing, and in some cases eliminating, direct risk exposure. One of the most promising avenues is the adoption of fully autonomous or remote-controlled tractors that can safely operate even in challenging environments, such as steep slopes or fields where other machinery is in motion. As a result, the operator can remain at a safe distance, monitoring operations via a tablet or remote console. In the domains of training and technical assistance, there is an increasing exploration of augmented reality, which enables operators to visualize instructions, maintenance procedures, or hazard warnings directly overlaid onto reality using headsets or mobile devices. Additionally, increasingly sophisticated user interfaces and self-diagnostic systems automatically detect malfunctions and propose real-time solutions.
However, this technological revolution brings new challenges: as automation increases, clarifying who should be deemed responsible in the event of machine error becomes urgent. Furthermore, the collection of sensitive data regarding the field and the operator necessitates robust measures to ensure privacy protection and cybersecurity. A hacker attack could not only disrupt productivity but also potentially cause environmental damage or endanger lives.
Finally, making these technologies accessible to all farms, including smaller operations, will be crucial. Public policies, economic incentives, widespread training, and technical support are essential to ensure that innovation does not remain the privilege of a few pioneers but instead becomes a shared asset. Only in this way can agricultural safety in the future be genuinely effective, inclusive, and sustainable.
Geofencing
Geofencing is a system that employs GNSS with RTK correction to establish precise virtual boundaries for a given operational area, which can be designated as a hazardous zone prone to potential overturning. If the tractor crosses these boundaries, the system automatically activates alarms, reduces speed, or even shuts down the engine. COBO's Sentinel system is designed to enhance safety measures during agricultural operations by implementing such geofencing features. Data is transmitted via the cloud for remote management and predictive maintenance.
