CILT • Technology by the forkful
October 17th 2006 You could be forgiven for thinking that the humble forklift truck does not change much. But that is a bit like suggesting today’s cars are no more sophisticated or safe than those of the late 1970s and that tomorrow’s will not have changed much, either. Instead, the truth is that in almost every conceivable way, the modern fork lift is infinitely more sophisticated than it used to be, and getting more sophisticated all the time, writes Robin Meczes.
Take cab ergonomics, for instance. Getting around the age-old problem of drivers having to pilot a vehicle in reverse when handling tall loads or in other reversing situations is a new development from Jungheinrich: a fully rotating cab. Featured on its new AC-powered EFG D30 electric counterbalanced truck, which was introduced in January, the rotating cab turns through 180 degrees to the right so the operator is facing the rear of the vehicle. This allows the truck to then be driven as normal in ‘reverse’, with the single exception that what was a rear-steer vehicle suddenly features a front steering axle.
The cab can also be rotated up to 30 degrees to the left,which,while not something that allows operators to drive ‘forwards’ in reverse, still makes it easier for them to look over their shoulder when reversing, if they prefer to twist to the left rather than the right. Although the cylindrical cab may not look it, it is every bit as strong as conventional overhead guard cabs, according to Juergen Butzke, product manager for electric counterbalanced trucks, Jungheinrich.
45 degree position
Not all cab improvements need to be quite this radical or sophisticated in order to bring real ergonomic benefits, however. Linde Material Handling’s new T20 SP and T24 SP-powered pallet trucks, for example, achieve a similar benefit in terms of avoiding spinal twist. The addition of an operating control pod set to provide a 45-degree driving position on a cushioned stand-on platform allows operators to travel either forwards or backwards without having to over-twist their neck or torso.
Combined with Linde’s ‘e-driver’ electronic control pod, which is designed for effortless single-handed steering when travelling in the 45-degree position or double-handed operations when facing the forks for picking or depositing loads, the result, according to Linde, is faster, safer work cycles with no heavy physical demand on the operator, who can maintain high efficiency levels without the usual fatigue.
Refined control
More refined control for drivers has been the focus over at Nissan, whose latest three-wheel electric counterbalanced trucks, the TX Syncro range, feature technology to ensure the drive wheels are always in the right position for straight line travel when reversing. Using a combination of angle sensors and power steering, the Syncro system always returns the driver’s steering knob to the same preselected position for straight line travel and the angle of the double rear-steer wheel is confirmed on an in-cab display. The system is said to overcome the difficulty of reversing in a straight line when coming out of racking or a stack of pallets: especially useful in racking where operators do not have the space to make mistakes. Doug Wyatt, National Technical And Service Manager, Nissan, says the system will be rolled out to the entire range in coming months.
Power on demand
Similar systems for preventing forks from lowering accidentally have been included in Mitsubishi’s latest FBNT three-wheel and FBN four-wheel counterbalanced trucks. Thanks to the new-generation controllers built into these trucks, they also have a ‘power on demand’ function, which senses the need for power and delivers it as necessary – for example, when starting on a gradient.
CANbus
One of the reasons for the very swift developments in truck electronics of late has been the inclusion by some manufacturers of a CANbus system: essentially, an onboard computer network fitted as standard that links various truck components or functions and makes information about the truck’s performance and condition more easily accessible.
Hyster and Yale are among the truck builders to have incorporated CANbus technology. Hyster has just introduced it, for example, on the new Fortens range of counterbalanced trucks, where it is key to the Pacesetter Vehicle Systems Manager, the electronic brain that manages all the truck’s electrical systems to optimise performance and increase reliability. The system also provides enhanced diagnostic capabilities and allows customisable truck performance.
Servicing and diagnostics have not just been enhanced by the provision of CANbus systems, however, but also by modern communications technology. On Atlet’s new Forte reach truck, for example, the onboard computer checks truck status every time the truck is started and, if a problem occurs, displays it on the dashboard display panel. The Truck Remote Access (TRAC) system, meanwhile, allows a user to connect a standard mobile phone to an input port on the vehicle and call Atlet’s service centre, which then uses the connection to interrogate the truck computer and diagnose the problem.
Onboard satellite
Caterpillar has been developing a similar system, though with the inclusion of GPRS technology on board the truck itself, rather than in a separate mobile phone, and with more of a fleet management slant than purely a servicing angle. The idea is that information about key fork lift parameters and performance is collected by a special onboard black box, then transmitted via Bluetooth wireless technology and GPRS-based communications back to a central database at MCFE’s headquarters in the Netherlands, from where it will be made available to fleet managers via a dedicated web site.
RFID
Radio frequency identification (RFID) technology, too, is starting to find favour in the lift truck sector. Among the latest developments is a prototype RFID-enabled fork lift truck announced jointly by RFID supplier Intermec and lift truck attachments manufacturer Cascade. Featuring an RFID reader built into the fork carriage and an in-cab display, the idea is that a truck can scan loads automatically as it picks them to warn operators if the load requires particularly sensitive handling, is beyond the truck’s lift capacity or requires a different fork
attachment to the one currently being used.
Operating costs
As elsewhere, meanwhile, the issue of high energy costs has also made its mark on lift truck technology. Still Materials Handling’s new R70 diesel trucks, for instance, now feature Intelligent Drive Management, a system that allows trucks to be driven at high speeds, but with much lower engine revs.
Under acceleration, the truck proceeds as normal but, once the desired travel speed has been reached, engine speed is reduced by around 30%, improving fuel efficiency by between 5% and 9%, depending on the application. There are also knock-on benefits in reduced engine noise and engine wear, says Still, resulting in a quieter, more comfortable driving environment and reducing emissions.
Fuel cell hybrid
Toyota has gone even further, developing a prototype fuel cell hybrid system that was unveiled last autumn and uses hydrogen as its main power source to produce electricity without combustion and with a total absence of carbon dioxide emissions. The main components of the system, including the fuel cell stack and high-pressure hydrogen tank, are mounted on a single module in a cartridge-type frame that can replace existing batteries in standard electric models.
Fuel cell lift trucks require minimal refilling and significantly less maintenance than standard electric fork lifts, says Toyota. The fuel cell system also ensures constant power delivery and performance, eliminating the reduction in voltage output that occurs as batteries discharge. As a result, fuel cell fork lifts should be ideally suited to conditions in large distribution centres, says the firm, where lift trucks often run continuous 24-hour shifts.
Articulated trucks
Articulated forklift trucks – such as the Flexi G3 produced by Narrow Aisle – are proven to maximise storage capacity and deliver greater operational efficiency. By using articulated forklift trucks, warehouse operators can increase pallet storage capacity at their facilities by anything between 30 and 50%.
For operators who choose the electric-powered version of the Flexi, Narrow Aisle has developed a roll out battery change facility. The batteries are contained in a ‘cassette’ type unit, which can be quickly and easily removed for fast and safe changeovers – enabling the truck to operate comfortably and efficiently in a multi-shift environment.
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