Forklift truck
Forklift tracking with IoT shows where every forklift truck is, which pallet it carries and where that pallet belongs. RFID, UWB and cameras replace manual scanning and document putaway, retrieval and loading automatically.
Forklift truck at a glance
Most frequent in the projects on this page
Users in these projects
Verified projects featuring Forklift truck
Automated loading documentation
Automatic load tracking with 1D/2D codes and cameras
40% process acceleration in the warehouse with IoT
Forklift tracking with RFID and UWB: pallets without scanning
In the solution examples, RFID readers on the truck detect which pallet it picks up, and UWB locates the vehicle inside the building. SICK's Automated Load Detect Ident System (ALDIS) detects loads with distance sensors and identifies them by RFID, laser scanner or camera. A Telematic Data Collector controls the sensors and transmits the data via Wi-Fi or cellular network. Outdoors, GPS provides the position, indoors UWB. ALDIS can be retrofitted regardless of manufacturer or year of build. At INTRANAV, data travels from a local edge unit via secured MQTT to the cloud and on to SAP Business One. For loading, TTS Automation and WAGO use industrial cameras on the trucks and at the dock, connected to a WAGO controller.
The examples come from transport and logistics as well as retail and wholesale. In a hall with almost 35,000 pallet spaces, TB International manages its forklift fleet with INTRANAV Smart Warehouse: the tablet shows the driver the nearest free storage location on an optimised route, and putaway and retrieval are booked in the ERP without scanning. In full-carton handling, the RFID implementation increased efficiency by almost 40 per cent. TTS Automation uses cameras to document the loading of dangerous goods vehicles. Podcast episodes #66 (INTRANAV, TB International) and #73 (Roland Avar, SICK) go into more detail.
Podcast episodes featuring Forklift truck
Forklift tracking: frequently asked questions
How does a forklift tracking system manage storage locations?
A forklift tracking system assigns a free storage location to each transport and exchanges orders and postings directly with the ERP system. At TB International, INTRANAV Smart Warehouse automatically creates a transport order from a digital pallet bundle, which is collected by the next available forklift truck. Completed putaway is posted in SAP Business One without scanning. Data flows from a local edge unit via MQTT to the cloud and via a REST API to SAP.
What does RFID on a forklift truck do?
RFID on a forklift truck automatically recognises which pallet, with which contents, is being picked up. At TB International, the trucks are fitted with RFID and UWB, and the high-bay racking also carries RFID labels. Pallets are therefore moved through all logistics zones without scanning. When goods are retrieved, the loaded truck passes through an RFID gate that checks the order for completeness and closes it in the ERP system.
How can proof of loading be documented automatically?
Proof of loading can be documented automatically with cameras at the dock and on the forklift trucks. In the project by TTS Automation and WAGO, the cameras identify the forklift, detect when it drives in and out and save an image of the load. A timestamp and order number are burned into the image, which is filed in the ERP. Previously, staff photographed loads with a tablet or digital camera and sorted the images by hand.
How does forklift location tracking work indoors and outdoors?
Forklift location tracking uses GPS outdoors and ultra-wideband radio inside the building to determine the position of the truck and its load. In SICK's ALDIS system, the positions are linked with the load's identification data, so it is always clear where the material, the pallet and the forklift are. The Asset Analytics software analyses the data. Retrofitting works regardless of the vehicles' manufacturer and year of build.
More assets in “Conveying and Handling Technology”
Automated guided vehicle (AGV)
An AGV system brings material automatically from the warehouse to the line when a central fleet controller coordinates the automated guided vehicles (AGV). With IoT, sensors trigger transport orders and vehicles from different manufacturers run in one system.
Crane
Predictive crane maintenance with IoT focuses on the cable carrier, which guides power and data cables to the trolley. Sensors report overload or breakage before the crane comes to a standstill and give maintenance and replacement recommendations.
Industrial robot
Predictive robot maintenance with IoT brings the condition and performance data of industrial robots together on one platform. Operators detect faults and wear before a robot comes to a standstill, and manufacturers identify maintenance cases remotely.
Conveyor belt
Conveyor belt maintenance with IoT relies on sensors that capture vibration, temperature and the condition of the belt and belt cleaners. Operators detect damage such as a torn belt early, plan maintenance as needed and avoid costly line stoppages.
High-bay warehouse
In a high-bay warehouse, IoT links storage locations, forklifts and warehouse management through real-time data. Staff see on large screens which orders are due next, and pallets are put away and retrieved without manual scanning.
Welding robot
A connected industrial welding robot delivers cycle times, piece counts and status messages in real time. Operators make downtime visible, balance the utilisation of their robot lines and integrate the robots into end-to-end order control.
IIoT Use Case user group
What no project tells you
What did the project cost? Which sensor didn't survive in the field? How did you get maintenance on board? 300+ industrial users discuss questions like these with each other every month, openly and without vendors in the room.
Frequent topics in these projects, bring your questions:
- Traceability
- Asset Tracking/ Track and Trace
- Digital Documentation
Online every month
Alternating tech and business focus
Users only
No sales pitches, exchange under NDA
300+ members
OT, IT and IIoT leads from industry
