Optimise manoeuvrability and control to boost materials handling productivity
How can you move and handle goods faster, without bumps and breakages? Improving forklift manoeuvrability and control is the key.
In a previous article, we set out the design priorities for fast lift trucks. Power and speed are important, of course, but at the same time we need to avoid accidents. Downtime, repairs and stock losses can seriously reduce productivity and profits.
At Cat® Lift Trucks, forklifts are designed to manoeuvre with speed, agility and precision. This allows operators to drive quickly around and between buildings, racking, people, and other obstacles – without hitting them. Excellent manoeuvrability is combined with smooth and precise control of all travel and hydraulic movements. In this way, we reduce the chance of loads being shaken, spilled and damaged.
Agile forklift manoeuvring
Compact dimensions are a great starting point if the lift truck is to be highly manoeuvrable in restricted spaces. You will find neat body shapes and small footprints throughout the Cat® counterbalance forklift and warehouse equipment portfolio. An interesting example of this can be found in our pioneering development of the stand-in and sit-on versions of stackers and power pallet trucks. These are actually more compact than platform models, so they require less aisle width. They also enable operators to drive confidently at higher speeds, by fully containing and protecting them within the truck’s structure.
‘Progressive’ or ‘adaptive’ electric power steering is an important aid to manoeuvring precisely and safely. It’s used, for example, in our electric counterbalance forklifts and in the stackers and power pallets mentioned above. It automatically adjusts the sensitivity of control according to speed. When the lift truck is moving slowly, it provides high precision for tight manoeuvres. When travelling fast and straight, it smooths out the response to steering movements to maintain stability.
Most of our electric counterbalance trucks also benefit from all-wheel steering systems, which give better grip, smoother turns and amazingly agile manoeuvring. They feature a +100⁰ rear turning axle, which enables instant side turns without having to make an initial backward movement.
Our three-wheel electric counterbalance forklifts were the first in the market to offer the option of 360⁰ steering. This allows the truck to turn 180⁰ and travel in the opposite direction in one smooth, fluid movement, without stopping. It also reduces G-forces, enabling higher turning speeds without destabilising and spilling the load. The same option is also available on our reach trucks and stand-in/sit-on power pallets and stackers.
Smooth lift truck control
Continuing advances in our AC motor and electronic controller technology make every travel and hydraulic movement smoother as well as faster. They apply to all trucks in our electric counterbalance and warehouse equipment ranges.
The advanced technology on Cat electric counterbalance forklifts between 1.4 and 5.5 tonnes includes our Responsive Drive System (RDS). RDS constantly adjusts hydraulic and travel performance characteristics in reaction to the driver’s behaviour. It monitors the speed of pedal and hydraulic control operation and adapts to his or her changing needs. All movements, stops and starts are smooth, so the load remains stable, and the driver enjoys the best possible user experience.
Our article on heavy lifting challenges goes into further detail on precise control of hydraulic functions in Cat electric counterbalance trucks. In addition to RDS, models such as our electric 4.0 to 5.5 tonne 80V range offer the SmoothFlow hydraulic system.
SmoothFlow overcomes difficulties posed by variation in load weight. In conventional forklifts, lifting behaviour changes considerably when handling items with different weights. SmoothFlow senses a load’s weight and makes automatic adjustments to ensure all mast and fork movements are smooth, precise and fast. The system also adjusts to maintain consistent performance when two or more hydraulic functions are used simultaneously.
Another aid to smooth performance on these trucks is automatic hydraulic control tuning. It reduces mast sway, and loss of positional accuracy, by limiting hydraulic and travel speeds when lifts exceed a certain height. In addition, passive sway control absorbs mast tilting forces at high lifts.
On our reach trucks, aids include automatic hydraulic motion control and Mast Tilt Control (MTC). Lift, lower, reach, tilt and side shift speeds are adjusted according to lift height, keeping all movements smooth, quiet and precise. Meanwhile, the MTC damping system reduces mast oscillations for faster and more stable load handling.
Advances across the Cat® counterbalance forklift and warehouse equipment product range
The summary above gives just a few examples. We apply the same design principles to our LPG forklifts and diesel forklifts, order pickers and tow trucks, for instance.
For further information on our comprehensive range, visit our product pages.
