Dump trucksare used on construction sites and in mining operations, where they must move and unload heavy loads quickly and efficiently, often on uneven surfaces and in harsh operating conditions.
During the work phases (loading, unloading, etc.) , it is essential to continuously monitor the movements of the body,the inclination of the vehicle and the parameters of the hydraulic circuit in order to ensure stability, reduce operational risks and protect the safety of the operator.
The use of linear position, rotarysensors,tilt sensors and pressure sensors improves operational safety, ensures continuity of work and increasesmachine reliability even in the most severe environments.
Requirements:
Driving pedals position control
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Steering angle control
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Hydraulic circuit pressure monitoring
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Articulated joint angle control
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Body's tipping angle measurement
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Body load detection
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Suspension position monitoring
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Vehicle tilt detection
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Requirement:
Driving pedals position control
Checking the position of the driving pedals is essential to ensure that the machine responds correctly and proportionally to the operator’s actions. In a tipper truck, inaccurate management of the acceleration and deceleration controls can compromise manoeuvrability, operational safety and driving comfort, especially when manoeuvring on uneven ground or in confined spaces.
A reliable detection system allows continuous monitoring of the position of the pedals, ensuring precise transmission of the command to the traction system. This improves vehicle control, reduces the risk of sudden movements and contributes to more stable and safer driving in all working conditions.
Solution:
Main features:
- Contactless Hall technology, which guarantees high measurement stability and long operating life
- Available with redundant output and with different electrical interfaces, analogue or digital
- E1 approved in accordance with ECE-R10
Thanks to these features, the GRA rotary sensor with shaft is an effective solution for controlling the position of the drive pedals, contributing to the safety, control precision and operational continuity of the tipper truck.
Requirement:
Steering angle control
Steering angle control is a key element in ensuring manoeuvrability, vehicle stability and operational safety of the tipper truck. During forward movement and manoeuvring, especially in confined spaces or on uneven terrain, inaccurate measurement of the steering angle can compromise the vehicle’s trajectory and increase the risk of uncontrolled manoeuvres.
An accurate detection system allows continuous monitoring of the angular position of the steering system, ensuring a consistent and predictable response of the vehicle to the operator’s commands. This improves directional control, reduces wear on mechanical components and contributes to smoother and safer driving in all operating conditions.
Solution:
Gefran offers the GRN shaftless rotary sensor, a robust and reliable solution designed to control the steering angle on mobile machines operating in harsh environments.
Main features:
- Contactless Hall effect magnetic technology, ideal for repetitive movements and long operating life
- Compact size and easy to install
- Offers high resistance to shock and vibration, ensuring solid performance over time
Thanks to these features, the GRN shaftless rotary sensor is an effective solution for steering angle control, helping to improve driving precision, vehicle stability and operational reliability of dump trucks.
Requirement:
Hydraulic circuit pressure monitoring
Monitoring the pressure of the hydraulic circuit is essential to ensure the proper functioning of the main functions of the tipper truck, such as body movement, steering control and suspension behaviour. Incorrect pressure values can compromise system efficiency, machine stability and operational safety, increasing the risk of breakdowns or machine downtime.
A reliable measurement system allows continuous monitoring of the pressure in the hydraulic circuits, ensuring that the actuators operate within the specified limits. This prevents overloadconditions , allows any anomalies to be detected promptly and maintains consistent machine performance during all phases of operation.
Gefran offers KM series pressure sensors, available with analogue and digital (KMC) outputs, designed for hydraulic applications on mobile machines.
Main features:
- They are compact in size, making them easy to install even in confined spaces;
- They guarantee high resistance to shock, vibration and high temperatures;
- They are SIL2/PLd certified, ensuring high standards of functional safety.
Thanks to these characteristics, the KM series pressure sensors are an effective solution for monitoring the hydraulic circuit, contributing to the safety, operational reliability and continuity of work of the tipper truck.
Requirement:
Articulated joint angle control
In articulated dump trucks, controlling the angle of the articulated joint is essential to ensure manoeuvrability, vehicle stability and safety during steering and handling. An inaccurate measurement of the articulation angle can negatively affect the vehicle’s trajectory, especially when carrying heavy loads or on uneven terrain.
A reliable detection system allows continuous monitoring of the articulation angle, ensuring precise management of the relative movements between the two sections of the vehicle. This improves directional control, reduces mechanical stress on the structure and contributes to smoother, more predictable driving in all operating conditions.
Solution:
Gefran offers the GRN shaftless rotary sensor, a compact and highly reliable solution, ideal for controlling the angle of the articulated joint in applications on mobile machines.
Main features:
- Contactless Hall effect magnetic technology, which guarantees precision and long operating life
- Design without mechanical shaft, which simplifies integration into the joint and reduces maintenance
- E1 approved in accordance with ECE-R10
Thanks to these features, the GRN sensor is an effective solution for controlling the angle of the articulated joint, contributing to vehicle stability, manoeuvring precision and operational reliability of the tipper truck.
Requirement:
Body's tipping angle measurement
Measuring the tipping angle of the body is a critical function for ensuring safety, vehicle stability and correct unloading operations. Inaccurate control of the lifting angle can lead to instability, especially with heavy loads or on uneven surfaces.
A reliable measurement system allows continuous monitoring of the angular position of the body during lifting and lowering, ensuring progressive and controlled movement. This prevents unwanted tipping, optimises unloading operations and protects the safety of the operator and the surrounding environment.
Depending on the construction approach and system architecture adopted by the manufacturer, the tipping angle of the body can be measured using different solutions.
Gefran offers the GRN shaftless rotary sensor, ideal when detection takes place directly on the tipper body’s rotation pin, and the GIG inclination sensor, suitable for measuring the tipper body’s angle of inclination with respect to the vertical or the vehicle chassis.
GRN shaftless rotary sensor
Main features:
- Contactless measurement technology for high reliability and long operating life
- Design without mechanical shaft, which simplifies integration into the joint and reduces maintenance
- Available with redundant output and with different electrical interfaces, analogue or digital
GIG inclination sensor
Main features:
- Available in single or redundant output versions
- Sensor housing sealed with resin to provide complete protection against external agents
- High resistance to shock and vibration
Thanks to these features, GRN and GIG sensors are effective solutions for measuring the tipping angle of the body, contributing to motion control, operational safety and overall reliability of the tipper truck.
Requirement:
Body load detection
Detecting the load in the body is essential to ensure operational safety, prevent overloading and optimise the use of the Dump truckduring transport and unloading. An incorrectly monitored load can compromise the stability of the vehicle, increase structural stress and reduce the overall reliability of the machine.
In tipper trucks, load assessment is commonly performed by measuring the pressure in the hydraulic circuit, which is related to the force exerted by the weight of the material being transported. A reliable detection system allows the body load to be continuously estimated, supporting the machine’s control logic and helping to prevent critical operating conditions.
Solution:
Gefran offers KM series pressure sensors, available with analogue and digital (KMC) outputs, designed for hydraulic applications on mobile machines.
Main features:
- Compact design, ideal for installation even in confined spaces;
- High resistance to shock, vibration and high temperatures;
- SIL2/PLd certified sensor, ensuring high functional safety standards.
Thanks to these features, the KM and KMC pressure transducers are an effective solution for detecting the load in the body, contributing to safety, machine protection and operational continuity of the tipper truck.
Requirement:
Suspension position monitoring
Monitoring the position of the suspension is essential to ensure vehicle stability, driving comfort and correct dynamic behaviour of the tipper truck, especially when transporting heavy loads on uneven terrain. Uncontrolled changes in attitude can adversely affect load distribution and the overall safety of the machine.
A reliable detection system allows continuous monitoring of the suspension position, providing useful information for controlling the vehicle’s attitude and adapting to different operating conditions.
Gefran offers the TWIIST linear position sensor, an innovative and reliable solution for monitoring the position of the suspension on dump trucks.
Main features:
- Patented multivariable technology, with integrated position and dynamic measurement
- Available with analogue and CAN bus outputs
- Designed for harsh mobile environments, resistant to shock, vibration and high temperatures
Thanks to these features, TWIIST sensors are an effective solution for monitoring the position of the suspension, contributing to vehicle stability, operational reliability and continuity of work for the tipper truck.
Requirement:
Vehicle tilt detection
Detecting the vehicle’s inclination is a fundamental function for ensuring the operational safety of the tipper truck, particularly during the loading and unloading phases of the body. Operations performed with the vehicle stationary, on surfaces that are not perfectly level, can generate unstable conditions, increasing the risk of overturning and compromising operator safety.
A reliable detection system allows continuous monitoring of the vehicle’s angle of inclination relative to the horizontal plane, providing key information to enable safety logic, operator alerts or critical function limitations.
Gefran offers the GIB inclination sensor, a compact and easy-to-install solution, and the GIG inclination sensor, also available with redundant outputs to support safety functions and critical applications.
GIB inclination sensor
Main features:
- Compact size and easy installation, ideal for integration in small spaces
- Available with analogue and digital outputs
- Designed to withstand impact, shock and vibration
GIG inclination sensor
Main features:
- Available with analogue or digital outputs, in single or redundant output configuration
- Sensor housing sealed with resin to provide complete protection against external agents
- High resistance to impact, shock and vibration
Thanks to these features, GIB and GIG sensors are effective solutions for detecting vehicle tilt, ensuring operational safety and overall reliability of the tipper truck.
Operating principle:
The Dump truckis designed for the transport and controlled unloading of bulk materials, coordinating the movement of the vehicle with the operation of the tipper body. During loading of the body, the machine must maintain vehicle stability and correct trim even on uneven ground, thanks to the interaction between the chassis, hydraulic system and traction system.
During the unloadingphase , the hydraulic cylinders control the lifting of the body, progressively adjustingthe tipping angle. The engine powers both the traction system and the hydraulic circuit, which coordinates the actuators responsible for tipping and auxiliary functions, ensuring movement control, operational safety and machine reliability in all working conditions.
Requirements and technology:
Dump trucks operate in harsh working environments, characterised by heavy loads, uneven surfaces, shocks and vibrations. In this context, it is essential to ensure stable and controlled operation of the machine, on which operational safety, continuity of work and vehicle reliability depend.
During the work phases, the machine must ensure precise control of the driving functions and body movements, keeping the steering angle, vehicle attitude, body tipping angle and hydraulic circuit pressureunder control . For this reason, it is essential to integrate a sensor system capable of continuously monitoring linear positions, angles, pressures and loads, helping to prevent instability and improve operator safety.
Gefran sensor solutions are designed to withstand shocks, vibrations, dust, water and extreme temperatures, ensuring reliable measurements even in the most severe operating conditions.
The main technological requirements include:
- Driving pedals position control
- Steering angle control
- Hydraulic circuit pressure monitoring
- Articulation joint angle control
- Body tipping angle measurement
- Load body detection
- Suspension position monitoring
- Vehicle tilt detection
Gefran offers a complete portfolio of linear position sensors, inclination sensors, rotary sensors and pressure transducers to support the development of safe, robust and reliable tipper trucks .
