Applications
Forklift trucks, commonly known as forklifts, are machines designed for handling, lifting, and positioning loads. Thanks to their ability to operate in confined spaces and handle heavy loads with high precision, they are an essential solution for material handling activities in warehouses, distribution centers, and production facilities.
The operation of the forklift truck is based on the integration of mechanical, hydraulic, and electronic systems that manage traction, mast lifting, and fork movement, as well as vehicle maneuverability. In this context, the use of linear, rotary, tilt, and pressure position sensors allows the main operating variables of the machine to be monitored, improving movement precision, operational safety, and efficiency.
Requirements:
Driving pedals position control
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Hydraulic circuit pressure monitoring
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Steering angle control
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Mast height adjustment
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Forks side adjustment
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Mast tilt control
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Requirement:
Driving pedals position control
In forklifts, the position of the drive pedals directly determines the response of the traction system and the forward speed of the machine. Accurate detection of the angular position of the pedals allows the on-board electronics to correctly interpret the operator’s intention, ensuring a smooth and proportional response of the vehicle.
Precise monitoring of the driving controls improves the maneuverability of the forklift, especially when operating in confined spaces such as warehouses and logistics areas. Reliable measurement of the position of the pedals also helps to ensure stable speed control when approaching the load and positioning the forks, increasing operational safety and precision.
To monitor the position of drive pedals, Gefran offers the GR3P and GRA rotary shaft sensors, designed for use on mobile machinery and in harsh industrial environments.
GR3P rotary sensor
Main features:
- Non-contact Hall effect magnetic technology, which guarantees measurement stability and long operating life
- Compact design combined with high resistance to shock and vibration
- Available with analog outputs
Rotary sensor with GRA shaft
Main features:
- Non-contact Hall effect magnetic technology, which guarantees measurement stability and long operating life;
- Robust design suitable for applications on mobile machines;
- Available with analog and digital outputs, also in redundant configuration.
Thanks to these features, Gefran rotary sensors enable reliable detection of the position of the drive pedals, improving vehicle control and the operational safety of the forklift truck.
Requirement:
Hydraulic circuit pressure monitoring
In forklifts, the hydraulic circuit is the system through which the power needed to operate the mast and the main load handling components is transmitted. The pressure of the hydraulic fluid directly determines the machine’s ability to lift, tilt, and position the load in a controlled and safe manner.
Continuous Hydraulic circuit pressure monitoring allows stable operating conditions to be maintained, prevents overloading of the hydraulic system, and enables any anomalies in the system to be detected promptly.
Solution:
Gefran offers KM series pressure sensors, available with analog and digital (KMC) outputs, designed for hydraulic applications on mobile machines.
Main features:
- Small size, allowing installation even in confined spaces
- High resistance to shock, vibration, and high temperatures
- SIL2/PLd certified, ensuring high functional safety standards
Thanks to these features, KM and KMC pressure sensors enable reliable monitoring of hydraulic circuit pressure, helping to improve the safety, efficiency, and operational reliability of forklift trucks.
Requirement:
Steering angle control
In forklifts, the ability to perform precise maneuvers is essential for operating in confined spaces such as warehouses, storage aisles, and loading areas. Accurate monitoring of the steering angle allows the vehicle control system to correctly interpret the operator’s maneuvers and ensure a stable trajectory during handling operations.
Precise measurement of the steering angle also improves the maneuverability of the forklift, reduces the risk of collisions with racks or loads, and increases operational safety during transport and positioning.
Solution:
For steering angle control, Gefran offers the GRN shaftless rotary sensors, designed for applications on mobile machines and harsh operating environments.
Main features:
- Non-contact Hall effect magnetic technology, which guarantees long operating life
- Compact, shaftless design, ideal for integration into steering mechanisms
- High resistance to shock and vibration, typical of mobile machine applications
Thanks to these features, the GRN sensor allows precise and reliable monitoring of the steering angle, improving vehicle control, maneuverability, and operational safety of the forklift.
Requirement:
Mast height adjustment
In forklifts, the mast is the structure that guides the vertical movement of the forks and allows the lifting and positioning of loads. Precise control of its position is essential to allow the operator to move the load accurately, especially during storage on shelves or picking at different heights.
Precise linear position adjustment allows for progressive control of the mast’s movement, improving load stability and reducing the risk of sudden movements.
Contactless Magnetostrictive - Rod Flange AISI 316 - Analogue Output
Draw wire sensor for linear position measurement with range from 1.8 to 8.3 m, available with analog and digital outputs.
For mast position adjustment, Gefran offers the RK-5magnetostrictive linear position sensor and the GSH-Slinear wire sensor, two alternative measurement technologies that allow the detection system to be adapted to the construction configuration of the forklift’s lifting system.
RK-5 magnetostrictive linear sensor
Main features:
- Non-contact magnetostrictive technology
- Direct installation inside the hydraulic cylinder, without external dimensions
- Measuring range up to 2.5 m
GSH-S linear wire position sensor
Main features:
- Non-contact Hall effect technology
- Robust structure, making the sensor suitable for outdoor installations
- Available with analog and digital outputs
Gefran sensor solutions enable precise monitoring of mast height, improving lift control and the operational safety of the forklift truck.
Requirement:
Forks side adjustment
In forklift trucks, lateral adjustment of the forks allows the position of the load to be adjusted in relation to the mast, facilitating picking and depositing operations on shelves or pallets. Precise control of this movement allows the operator to align the load correctly, reducing the risk of collisions with warehouse structures or other materials.
Monitoring the position of the side shift system also improves the precision of handling operations, optimizes maneuvering times, and increases safety during loading and unloading.
To control the lateral position of the forks, Gefran offers the RK-5 magnetostrictive linear position sensor and the TWIIST multivariable linear sensor , ideal solutions for precise monitoring of movements in fork translation systems.
RK-5 magnetostrictive linear sensor
Main features:
- Non-contact magnetostrictive technology
- Direct installation in the hydraulic cylinder
- Measuring range up to 2.5 m
TWIIST multivariable linear sensor
Main features:
- Simultaneous measurement of linear and angular position with a single sensor
- Compact solution, suitable for integration into fork handling systems
- Available with analog and digital outputs
Gefran sensor solutions enable precise monitoring of the lateral position of the forks, improving load alignment, maneuvering precision, and the operational safety of the forklift.
Requirement:
Mast tilt control
In forklifts, the tilt of the mast stabilizes the load during lifting and transport, preventing imbalances that could compromise the safety of the machine and the operator. Precise control of the tilt angle keeps the load correctly positioned in relation to the vehicle’s center of gravity, especially during handling at different heights.
Accurate monitoring of mast tilt also helps improve precision in load storage and retrieval operations, reducing the risk of collisions with racking or other structures. Reliable tilt angle measurement is therefore a key element in ensuring stability, safety, and efficiency in material handling applications.
For mast tilt control, Gefran offers the GIB tilt sensor and the GR3P rotary sensor with shaft, two alternative measurement technologies that allow the detection system to be adapted to the mechanical configuration of the tilt mechanism.
GIB inclination sensor
Main features:
- MEMS technology for precise measurement of inclination with respect to gravity
- Compact dimensions, ideal for integration even in small installation spaces
- High signal stability, even in the presence of vibrations
GR3P rotary sensor with shaft
Main features:
- Contactless Hall effect magnetic technology
- Available in two versions (32 mm and 50 mm center distance), with customizable mechanical configurations, different mounting options, and accessory levers
- High resistance to shock and vibration.
Gefran sensor solutions enable precise control of mast inclination, improving load stability and the operational safety of the forklift during work operations.
Operating principle:
The forklift truck is designed to lift, transport, and position loads using a system consisting of a mast, fork carriage, and hydraulic circuit. The mast guides the vertical movement of the forks, while the hydraulic cylinders generate the force necessary to lift the load andtilt the mast, allowing the load to be stabilized during the various handling phases.
At the same time, the traction and steeringsystems allow the vehicle to operate with high maneuverability even in confined spaces, typical of logistics and industrial environments. During operation, linear position sensors, rotary sensors, inclinometers, and pressure transmitters monitor key parameters such as the position of the steering controls, the steering angle, the height of the mast, the position of the forks, and the pressure of the hydraulic circuit.
Continuous monitoring of these variables allows the on-board electronic systems to optimize control of the machine’s movements, improving operational precision, operator safety, and efficiency in material handling operations.
Requirements and technology:
Forklifts operate in logistics and industrial environments characterized by intensive work cycles, frequent load handling, and often limited operating spaces. Under these conditions, precision of movement, load stability, and control of key operating parameters are essential to ensure safe and efficient operations. Continuous manoeuvres, load variations and mechanical stresses require reliable measurement systems capable of providing accurate data in real time.
The main technological requirements include:
- Driving pedals position control
- Hydraulic circuit pressure monitoring
- Steering angle control
- Mast height adjustment
- Forks side adjustment
- Mast tilt control
Gefran meets these requirements with a complete range of linear position sensors, rotary sensors, tilt sensors, and pressure sensors, designed to ensure precision, reliability, and continuous operation in forklifts and, more generally, in industrial and logisticsmaterial handling applications.