Applications
Thanks to the combination of a hydraulic boom, front bucket and all-wheel drive system, the wheel loader guarantees high productivity and manoeuvrability even on difficult terrain.
During excavation, compaction, lifting, loading and unloading operations, it is essential to maintain constant control over the steering angle, boom inclination and bucket load in order to ensure smooth movements and stability in all working conditions.
The integration of rotary sensors, linear position sensors and pressure sensors improves operational precision, optimises cycle times and increases operator and machine safety.
Requirements:
Driving pedals position control
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Boom and bucket position adjustment
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Steering angle control
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Hydraulic circuit pressure monitoring
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Hydraulic pump flow rate adjustment
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Control of the rotation angle of the articulation joint
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Requirement:
Driving pedals position control
Accurate control of the position of the pedals and control levers is essential to ensure smooth and safe operation of the wheel loader.
A precise detection system optimises engine response according to load and operating conditions, improving control sensitivity and operator comfort.
Continuous measurement of the angular position of the pedal and/or lever ensures immediate control of the power delivered, reduces energy consumption and increases the overall safety of the machine, ensuring a constant and predictable response at every stage of work.
Solution:
Gefran offers the GRA rotary sensor with shaft, a robust and versatile solution ideal for controlling the position of pedals and control levers in wheel loaders.
Main features:
- Hall contactless technology, which guarantees high measurement stability and long operating life;
- Available with redundant output and various analogue or digital electrical interfaces;
- E1 approved in accordance with ECE-R10.
Thanks to these features, the GRA rotary sensor is a reliable and durable choice for applications that require precise control, safety and continuous operation over time.
Requirement:
Boom and bucket position adjustment
Accurate adjustment of the position of the boom and bucket is essential to ensure maximum efficiency and stability of the wheel loader at every stage of the work cycle.
A precise detection system allows continuous management of boom inclinations and bucket opening angles, optimising load capacity and material distribution.
Constant monitoring of positions reduces the risk of overload or loss of stability, improves productivity and contributes to smoother and more controlled movement management.
Gefran offers a complete range of solutions for adjusting the position of the boom and bucket of wheel loaders, combining linear and rotary sensors based on contactless technology to cover all measurement needs.
RK-5 linear position sensor
Main features:
- Direct installation inside the hydraulic cylinder, without external encumbrance
- Contacless magnetostrictive technology that eliminates wear and guarantees long life
- High resistance to shock, vibration and contaminants
GRA rotary sensor with shaft
Main features:
- Available in single or redundant output versions for high safety requirements
- Supports analogue and digital interfaces (CANopen, SAE J1939) for easy integration
- Robust design, resistant to shock and vibration
Thanks to this integration of linear and rotary measurement technologies, Gefran offers a complete and reliable control system capable of ensuring consistent performance even under the most demanding operating conditions.
Requirement:
Steering angle control
Steering angle control is an essential requirement for ensuring precise and safe manoeuvrability of the wheel loader. A reliable detection system allows the operator to manage the vehicle’s movements with greater accuracy, even in confined spaces or during complex operations. This helps to reduce the risk of instability and component wear, improving the machine’s operational efficiency and safety.
Solution:
To ensure precise and reliable steering control, Gefran recommends the GRN shaftless rotary sensor.
Main features:
- Contactless Hall effect magnetic technology, ideal for repetitive movements and long operating life;
- Compact in size and easy to install;
- High resistance to shock and vibration, ensuring solid performance over time.
Thanks to these features, the GRN sensor guarantees precise and stable steering angle control, improving manoeuvrability and overall machine safety.
Requirement:
Hydraulic circuit pressure monitoring
Monitoring the pressure inside the hydraulic circuit is crucial to ensuring the efficiency and operational reliability of a wheel loader. Continuous and accurate monitoring of pressure values allows for the timely detection of any anomalies, preventing breakdowns and reducing machine downtime. This function optimises the performance of the hydraulic system, ensuring the correct use of available power and helping to increase safety, productivity and the overall life of the components.
Solution:
For precise and safe control of hydraulic circuit pressure, Gefran recommends the KM series pressure sensors.
Main features:
- Compact in size, making them easy to install even in confined spaces;
- High resistance to shock, vibration and high temperatures;
- SIL2/PLd certified, ensuring high standards of functional safety.
Thanks to these features, KM pressure sensors are a practical and robust solution for monitoring hydraulic circuit pressure, combining safety, efficiency and reliability.
Requirement:
Hydraulic pump flow rate adjustment
Hydraulic pump adjustment is a fundamental aspect of the correct functioning of on-board power systems. Accurate control of valve opening and closing allows for optimal modulation of fluid flow, adapting performance to actual operating requirements. This precise management not only improves the energy efficiency of the circuit, but also helps reduce component wear, increasing the overall life of the system and ensuring greater reliability and safety in operations.
Solution:
To meet the need for precise adjustment of the hydraulic pump flow rate, Gefran recommends the GRN shaftless rotary sensor.
Main features:
- Compact size for easy integration in confined spaces;
- High resistance to vibrations, ensuring stability and durability over time;
- Available with analogue and digital interfaces.
Thanks to these features, the GRN allows precise and continuous control of hydraulic systems, helping to improve operational efficiency.
Requirement:
Control of the rotation angle of the articulation joint
In articulated wheel loaders, the central connection between the front and rear frames allows for high manoeuvrability, even in confined spaces or on difficult terrain.
To manage steering movements safely and smoothly, it is essential to monitor the angle of rotation between the front and rear axles.
An accurate detection system provides real-time information on the relative position of the two sections of the chassis, improving vehicle stability and steering control precision.
This type of control reduces the risk of loss of traction or sudden manoeuvres, increases operator safety and helps to optimise productivity in the various operating phases of the vehicle.
Solution:
For controlling the rotation angle of the articulation joint, Gefran offers the GRN shaftless rotary sensor, a compact and highly reliable solution.
Main features:
- Contactless Hall effect magnetic technology, which guarantees precision and long operating life;
- Mechanical shaftless design, which simplifies integration into the joint and reduces maintenance;
- E1 approved in accordance with ECE-R10.
The GRN sensor ensures stable and accurate detection of the rotation angle, improving directional control and operational safety of the articulated wheel loader.
Operating principle
The wheel loader is equipped with an articulated boom operated by hydraulic cylinders that allow the front bucket to be lifted, tilted and controlled during excavation, compaction and loading/unloading operations.
The engine transmits power to the traction system and the hydraulic circuit, which coordinate the movements of the lifting boom, bucket and steering, ensuring efficiency, precision and operational continuity.
During operation, linear position sensors and rotary sensors detect the angle of the boom and the machine’s attitude, while pressure sensors monitor the load on the hydraulic circuit, helping to maintain stability and operational safety. Thanks to constant monitoring of these parameters, the wheel loader can operate with maximum efficiency even on uneven terrain or with variable loads, reducing cycle times and optimising performance.
Requirements and technology
Wheel loaders operate in harsh environments, where power, precision and consistent reliability over time are required. During the loading, transport and unloading of materials, the machine must ensure smooth movements, chassis stability and operator safety even on uneven ground or with variable loads.
To achieve the best performance, it is essential to integrate an advanced sensor system capable of accurately monitoring key operating variables, such as the position of critical components (boom, bucket, etc.) and the pressure of the hydraulic circuits, improving the productivity and durability of the machine.
Gefran sensor solutions are designed to withstand shock, vibration, dust, water and extreme temperatures, ensuring reliable measurements in all operating conditions.
The main technological requirementshs include:
- Driving pedals position control
- Boom and bucket position adjustment
- Steering angle control
- Hydraulic circuit pressure monitoring
- Hydraulic pump flow rate adjustment
- Articulation joint rotation angle control
Gefran offers a complete range of sensors including linear and angular measurement, as well as pressure transducers to support wheel loader manufacturers in developing safe,efficient and reliable machines.
