Materials handling attachments come with the promise of improved productivity and safety
Considering all the innovation that has taken place in the materials handling sector in the recent past – the ongoing electrification of the sector, the rise of automation and connectivity, the talk of the “Warehouse of the Future” and so on – inevitably returns us to some familiar themes.
All this change has been predicated on safety (of personnel, plant and product), efficiency, productivity, and cost minimisation. It has been about ensuring that materials handling operations operate as effectively and efficiently as possible.
Here, it is important to note that no two materials handling operations are the same. For example, the handling of food products involves a different set of considerations and requirements to, say, working at heights.
This is where materials handling attachments come in. The beauty of these products is that they make it possible to fine tune a forklift’s operation to fit a specific application. They simplify the tasks of handling liquids, working in narrow aisles, and so on. In this way, they represent an extra set of tools for operations motivated by the above-mentioned goals, to turn to.
With this in mind, here is a selection of some of the latest and most innovative materials handling attachments currently on the market.
Sideshifters and fork positioners
Cascade Corporation offers a range of electric attachments, designed for use with automated guided vehicles (AGVs). Available as part of the company’s Electrix range, these include sideshifters, fork positioners, single-doubles, carton clamps, and rotators.
Available from Cascade Corporation, these electric carton clamps are highly energy efficient
Leveraging electric actuation and low-friction bearing systems, the attachments are highly energy-efficient, ensuring longer AGV battery life, while also offering the ability to increase an AGV’s handling capacity per cycle.
“Electric actuation offers real-time positioning and diagnostic data, which has been well-received by customers especially when it comes to predictive maintenance,” says Felipe Goitre, global product manager, Cascade Corporation.
Because they include no hydraulic components, these all-electric attachments lower total system costs and eliminate the risk of hydraulic oil leaks.
“Without the risk of leaking attachments, Electrix attachments are more environmentally friendly and perfect for working in clean environments such as food, medical, biotech, and electronics,” says Goitre.
“All-electric actuators offer precise controllability which means more accurate load positioning, reducing downtime, and ensuring optimum AGV and attachment performance.”
On top of this, information, like actuator cycle counts and utilisation rates, can be easily transmitted to the AGV’s systems, for use in predictive maintenance and workflow analysis.
Digital solutions
Cascade Corporation also offers two digital solutions, namely Cascade Activweigh, a weighing carriage solution; and Sensor Forks, attachments designed to improve visibility for forklift operators.
Activweigh is a patented, carriage-based scale integrated with “Weigh-In-Motion” capabilities, sideshifting, and fork positioning functionality, all packaged as a compact integral or hang-on unit.
“Activweigh allows forklift operators to easily approach a load, adjust the fork spacing, lift, and immediately weigh the load while the forklift is in motion – saving valuable time in fast-paced warehouse environments,” says Goitre.
Suitable for use with forklifts and AGVs, the attachment’s compact design improves manoeuvrability for the end user. According to the company, it is particularly effective in measuring solid and liquid materials, making it suitable for operations that require precise ingredient handling.
Meanwhile, Sensor Forks use a built-in digital camera and sensor package to provide drivers with a clear view of fork placement.
“In addition to the camera on the forks, a wide-angle auxiliary camera can also be mounted on strategic points of the lift truck, including the mast or load backrest, to provide an additional point of view for drivers,” says Goitre.
This solution makes it possible for forklifts drivers to easily read labels or product stock keeping units (SKUs) on high-up bins, crates, or pallets and can also assist with navigating difficult handling situations that require increased precision.
“This extra handling awareness can help avoid overdriving loads, reduce the risk of fork punctures and prevent costly damage,” Goitre adds.
Clamping pressure control system
One clear benefit of forklift attachments is that they make it possible to fine tune a forklift’s operation to fit a specific application. The handling of home appliances is a good example.
The Bolzoni Easy Move 4.0 relieves the forklift operator from paying attention to the amount of force applied
“In home appliances handling, there is a need to reduce load damage and increase productivity,” says Carlo Fallarini, global marketing director with Bolzoni Group.
“With an automatic clamping force control, such as the Bolzoni Easy Move 4.0, the forklift operator is relieved from paying attention to the amount of force applied to the load. The system has the capacity to first recognise the load to be handled, and then set the force required to correctly clamp it.”
A Wi-Fi-connected, fully automatic electronic clamping pressure control system, Easy Move 4.0 ensures damage-free handling in home appliance logistics.
Employing advanced light signal driving assistance technology, it enables even inexperienced operators to handle washing machines, refrigerators, ovens, dishwashers, and other consumer products without the threat of damage.
According to Fallarini, installing the attachment involves a similar amount of effort to that of conventional attachment installations.
“You usually need an electric power connection at the carriage but some of them, for example cameras and laser, can also work on a rechargeable battery,” he says.
Because it is Wi-Fi connected, the system is able to send handling, GPS and technical information to a web portal for analysis by management.
Indeed, according to Fallarini, it is able to provide international corporate supervisors access to this data as it applies to all logistic locations and all equipment in operation.
Paper roll clamps & telescopic forks
stabau GmbH offers products like the S 18-RKP paper roll clamp and the S 5 TGH telescopic fork, both of which are designed to make materials handling more efficient, safer and more economical.
The S 18 RKP paper roll clamp features a new 180-degree rotary drive
“The S 18 RKP paper roll clamp has been specially developed for handling paper rolls and has a new 180-degree rotary drive,” says Stefan Pinter, sales manager export at stabau GmbH, adding that the attachment’s optimised arm geometry and rounded contact plates ensure damage-free handling of rolls.
The paper roll clamp is available in various load capacity classes and for different roll diameters. It is flexible and suitable for use in numerous industrial sectors. Recommended for installation on forklifts, telehandlers or reach stackers, it can also be used for stationary equipment and implemented into production processes.
“The paper roll clamp minimises the risk of damage to sensitive paper rolls thanks to its adapted gripping geometry and ability to individually regulate contact pressure,” says Pinter.
Meanwhile, the company’s S 5 TGH telescopic fork enables one-sided truck loading and storage in double racking.
Thanks to the integrated forced synchronisation it can also be used as an extension fork and offers synchronised movement without an additional valve. According to Pinter, it can be combined with fork positioners or double pallet handlers, and so on.
“The telescopic forks reduce the space required when loading trucks and increase efficiency when loading and unloading, as well as when storing in double racking,” says Pinter.
“They also replace manual fork extensions and allow the fork length to be adjusted quickly. As well, telescopic forks substitute load extenders in case of fork handling.”
Featuring a robust design for a long service life and low maintenance requirements, it ensures improved visibility and higher residual capacity values compared to alternatives. It is designed for easy integration into existing forklift systems and is suitable for mounting on different fork carriers.
Intelligent forks
VETTER, the German-based supplier of Smartfork, an intelligent fork that incorporates additional camera and sensor technology to increase safety during materials handling processes, has released Smartfork Basic.
Smartfork is designed to increase safety during materials handling processes
Intended to map the complexity of the product in simple and clear kits, Smartfork Basic consists of a standard fork and one of three Smartfork forks.
“More specifically, we are talking about the Smartfork Frontcam or the Smartfork Sidecam for improved visibility and ergonomics when handling goods; and the Smartfork Laser, which acts as an aiming aid when storing and retrieving goods,” says Simon Staniczek, product manager at VETTER.
The three different versions are all intended to help forklift operators to work more safely and efficiently.
The Smartfork Frontcam, a camera integrated into the fork tip, ensures that even when goods are picked up and the view is therefore obstructed, the driver can still see ahead, and any obstacles can be detected at an early stage.
The Smartfork Sidecam, a camera integrated into the side of the fork blade, helps the driver drive safely into load carriers, as both forks are visible on the monitor in the cab. This is particularly helpful for drivers working at heights, where visibility is often restricted.
And finally, the Smartfork laser is a green line laser integrated into the tip of the forks, which also helps with aiming and driving into load carriers.
“The clear advantage is that the Smartfork Basic is not individually assembled and manufactured beforehand,” says Staniczek. “The basics are in stock at VETTER so that the kits can be delivered immediately.”
Asked about the integration of the system into existing operations, Staniczek notes that Smartfork Basic is supplied with a wiring diagram and all the necessary components. At the same time, he emphasises that installation must be carried out by a specialised forklift dealer.
Smartfork Basic offers two flexible installation options – either as a wireless version or with a mast cable. Both options are designed to ensure that specialist personnel can carry out installation quickly and easily.
“Safety is of course the most important factor with the Smartfork. Thanks to the camera and sensor technology, safe entry into load carriers is guaranteed and the goods are, for example, not accidentally pushed through the rack,” says Staniczek.
“This ensures that damage is actively reduced. In addition, the cameras provide a clear view to the front and better visibility, even when goods are being picked up, in order to detect hazards at an early stage and prevent accidents.”
In other words, like the various other materials handling attachments mentioned above, Smartfork Basic has a clear role to play in ensuring that the applications in which it is employed are as problem-free, efficient and productive as possible. And, in this way, it helps ensure the success and profitability of the organisation involved.
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For this report we interviewed the following industry specialists: