Applications
A telehandler is a multi-purpose machine widely used in construction sites and for industrial handling. The combination of extendable boom, rotating wheel and stabilisers allow it to lift, transport and position load even at great heights and distances. The integration of advanced sensors guarantees constant control of stability, precision in manoeuvres and safety in the most complex operating conditions.
Requirements:
Driving pedals position control
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Steering angle control
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Boom position detection
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Vehicle tilt monitoring
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Stabilizers position adjustment
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Hydraulic circuit pressure monitoring
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Requirement:
Driving pedals position control
Accurate control of the position of the driving control pedals (e.g. accelerator) is essential to ensure maximum precision in the management of the movements and performance of a telehandler. A reliable detection system allows the operator to modulate speed and power, making manoeuvres smoother and safer. This reduces energy consumption, optimises the performance of the machine and extends its useful life.
Solution:
Gefran offers the GRA rotary sensor, a robust and versatile solution that can guarantee stable performance.
- Non-contact Hall technology guarantees measurement stability and long life.
- It is available with redundant output and with different electrical interfaces, both analogue and digital.
- Resistant to shocks, vibrations and high temperatures.
Requirement:
Steering angle control
The control of the steering angle is an indispensable requirement to ensure safe and efficient manoeuvrability of the telehandler during the vehicle positioning phases. An accurate detection system allows the operator to manage movements with precision, reducing the risk of errors and improving stability even in confined spaces or on complex terrain. This results in greater productivity, protection of the integrity of the machine and use in accordance with safety standards.
Solution:
For precise and reliable steering control, Gefran offers the GRN rotary sensor without shaft because:
- it uses non-contact Hall-effect magnetic technology, ideal for repetitive movements and long operating life.
- it is compact and simple to install.
- it is highly resistant to shocks, vibrations and water, ensuring consistent performance even in harsh environments.
Requirement:
Boom position detection
Accurate control of the linear and angular position of the telescopic boom is essential to ensure precise and safe movements during lifting operations. A reliable detection system allows the operator to accurately adjust extension and inclination, ensuring optimal positioning of the load even in complex operating conditions. This functionality reduces the risk of error while improving the stability and production efficiency of the machine in material handling activities.
For the accurate and reliable monitoring of the boom, Gefran offers the GSH-A sensor:
- 2-in-1 sensor, which allows operators to measure linear position and tilt.
- available with redundant outputs for both linear and tilt measurement.
- robust and compact design, suitable for installation inside the boom or outside.
Requirement:
Vehicle tilt monitoring
Monitoring the inclination of the base of a telehandler is crucial to ensure operational stability and safety. Measurements allow the detection of critical tilts in relation to the ideal position, reducing the risk of rollover. This function ensures stable support even when working on uneven ground, protects the operator and machine and improves the efficiency of lifting manoeuvres, ensuring the machine’s reliability and useful life.
Solution:
Chassis tilt monitoring is essential to ensure the stability and safety of the entire vehicle, especially when operating on uneven terrain. For this need, Gefran offers the GIB inclinometer, which is:
- a sensor with a compact design, which simplifies installation even in small spaces.
- designed to withstand collisions, shocks and vibrations.
Because of their precision, robustness and compatibility with safety systems, Gefran inclinometers are the ideal solution for ensuring the stability of a mobile machine’s base.
Requirement:
Stabilizers position adjustment
Correctly positioning the stabilisers is essential to ensure the stability and operational safety of telehandlers. Accurate monitoring makes it possible to verify that each stabiliser is correctly extended and well anchored to the ground, reducing the risk of imbalances or overturning during lifting operations. This allows the operator to work in a safer and more controlled way, increasing the efficiency of the manoeuvres and prolonging the life of the machine.
To ensure the correct positioning of the stabilisers and ensure machine stability, Gefran offers a linear-by-wire position sensor, combined with a pressure transmitter.
GSH-S wire position transducer
- non-contact Hall-effect technology for a long operating life.
- robust design, designed to withstand shocks and vibrations.
- available with digital and analogue interfaces.
KM pressure sensors
- compact design, easily integrated even in small spaces.
- resistance to shocks, vibrations and high temperatures.
- SIL2/PLd certificates, which guarantee high standards of functional safety.
Requirement:
Hydraulic circuit pressure monitoring
Pressure monitoring of the hydraulic circuit is an indispensable function to ensure the efficiency and operational reliability of telehandlers. An accurate control system allows the real-time detection of any anomalies or variations against the optimal values, preventing failures that could compromise safety and cause machine downtime. This function optimises the performance of the hydraulic system, reduces maintenance costs and increases the life of the components.
Solution:
For the precise and safe control of the pressure in the hydraulic circuit, Gefran recommends the pressure transducers of the KM series because:
- they are small in size, which makes them easy to install, even in limited spaces.
- they guarantee high resistance to shocks, vibrations and high temperatures.
- they are SIL2/PLd certified, ensuring high standards of functional safety.
Operating principle
The telehandler combines vertical lifting and horizontal movement functions through an extendable boom mounted on a rotating turret, allowing it to reach loads positioned at different heights and distances. The engine transmits power to the hydraulic systems that operate the boom, bucket, or forks, while the stabilizers ensure balance and stability even during the most demanding lifting operations. The cab houses the main controls and management systems that handle steering, boom extension, and attachment positioning.
To ensure all these operations are performed safely, accurately, and efficiently, the telehandler must rely on continuous monitoring of mechanical, hydraulic, and stability parameters.
Requirements and technology
Telehandlers must ensure stability, safety, and precision during lifting and handling operations involving heavy loads or people—often at great heights and with the boom fully extended. For this reason, they must integrate reliable sensor solutions capable of withstanding vibrations, shocks, dust, moisture, and extreme temperatures.
Key technology requirements include:
- Driving pedals position control
- Steering angle control
- Boom position detection
- Vehicle tilt monitoring
- Stabilizers position adjustment
- Hydraulic circuit pressure monitoring
Gefran offers a complete portfolio of linear position sensors, rotary sensors, tilt sensors and pressure sensors, designed to support telehandler manufacturers in the development of safe, efficient and durable machines.
