How Forklifts Operate

While most people have a general understanding of forklifts, there are numerous types, power options, sizes, and modern innovations that make up these essential machines. Some are used on challenging construction sites to lift heavy materials, while others autonomously navigate through advanced warehouses. Regardless of their environment, forklifts are indispensable in most warehouses and vital to various industries.

Though forklifts might appear more practical than innovative, they are small in size—similar to a compact car—yet they can carry loads that weigh tons, lifting them to impressive heights without tipping over. These machines operate tirelessly day in and day out, moving heavy materials to ensure smooth operation in industries such as manufacturing, automotive, and aerospace.

Forklifts have been essential for nearly a century, helping us accomplish tasks with greater efficiency. From battery-powered to liquid propane or hydrogen fuel cell forklifts, these machines continue to play a vital role in the efficient movement of goods, much as they did when first invented. Without them, modern manufacturing and shipping would be far less effective.

In the upcoming pages, we’ll explore the invention of the forklift, its rise to popularity, the essential components of a forklift, and how modern innovations are enhancing these machines. If you’ve never been interested in forklifts, you might be surprised by the complexity and advancements they’ve gone through.

History of Forklifts

Like many great inventions, the forklift was developed out of necessity. In 1917, the Clark Company, known for making axles, created the 'Tructractor' to transport materials around their factory. As others visited and saw it in action, they placed orders for similar machines. A few years later, hydraulic-powered lifts were introduced to enhance the lifting capability. In 1923, Yale introduced the first truck with forks designed to lift loads off the ground and an elevated mast that extended beyond the truck’s height. This Yale truck is considered the first forklift [source: MHEDA Journal].

Several key events, like the introduction of the standardized pallet in 1930 and the impact of World War II, led to a significant increase in forklift production. These advancements provided a way to move heavy loads more efficiently. As the demand for forklifts grew, so did their usage, leading to the development of rechargeable batteries that could power forklifts for up to 8 hours.

In the 1950s, as warehouses began to grow vertically rather than horizontally, forklifts were designed to lift loads up to 50 feet (15.2 meters), a significant increase in height. To address the challenges of handling heavier loads at greater heights, safety measures were introduced, such as a protective cage for operators to prevent falling materials and a backrest to secure the load during lifting. Further safety advancements emerged in the 1980s, including the addition of operator safety restraints and improved balance technology for forklifts.

On the following page, we will explore the fundamental components that make up a forklift and how each part functions in unison.

Forklift Construction and Classifications

While most people can recognize a forklift, few know that there are actually seven distinct classifications of forklifts (also known as industrial trucks). These classifications, established by the Occupational Safety and Health Administration (OSHA), include the following types of forklifts:

[Source: OSHA]

The forklift classifications listed above provide key differences between various types, including tire types, power sources, and even the terrain they are designed for. Forklifts may be equipped with pneumatic tires, made of durable rubber for outdoor use, similar to your car tires. Alternatively, forklifts may have solid tires (also called cushion tires), which are solid rubber and typically used for indoor operations on smooth, hard surfaces [source: Forkliftbiz.com].

Beyond the tires, forklifts consist of several essential components. These include:

[Source: Forkliftbiz.com]

Forklifts can be equipped with various attachments, such as those for carrying barrels instead of lifting pallets. Each forklift class is tailored for specific load types and work environments. To operate a forklift, operators must first pass a test that is specific to the type of forklift they will be using.

A specific type of forklift commonly found on construction sites is the rough terrain forklift. These machines are designed to lift construction equipment, roofing materials, bricks, lumber, and other heavy items. They are capable of lifting a load as large as a pickup truck to the height of a four-story building.

Next, explore how forklift technology is advancing and the impact it has on the way we transport heavy loads.

Evolving Forklift Technology

While forklifts have maintained their core purpose over the years — transporting heavy loads from one location to another — the technology that makes it possible is continuously improving. The forklift industry has made significant strides in areas like power sources, mobility, and automation, offering even greater versatility from an already adaptable vehicle.

More eco-friendly technologies are being integrated into forklifts, driven by the rise in fuel costs. Additionally, some energy-efficient forklifts can operate 20 to 30 percent longer than traditional internal combustion engine forklifts. In 2010, 63 percent of forklift orders were electric, a trend that is expected to remain above 60 percent in the years ahead [source: MHEDA Blog].

The Yale Company has developed a battery-powered forklift equipped with regenerative braking, which sends power back to the batteries when the forklift slows down, and can also recover energy when lowering a load. In addition to battery-powered forklifts, alternative clean fuels like liquid propane, clean diesel, and hydrogen fuel cells are also being used as power sources.

Forklifts have not only become more environmentally friendly but have also seen a transformation in mobility with the introduction of the Sidewinder forklift. Manufactured by Vetex, the Sidewinder can move in any direction. Unlike traditional pneumatic or solid tires, it uses rollers that can change direction. This forklift can overcome obstacles up to 3 inches (7.6 centimeters) tall and navigate a 40-foot (12.2-meter) long beam through a narrow entry while driving sideways, tasks that would be challenging or impossible for conventional forklifts.

A notable advancement in forklift technology is the development of the automated forklift. These machines use specialized guidance systems to navigate autonomously through warehouses or buildings, handling tasks such as picking up and delivering loads automatically. Automated forklifts are commonly employed in industries like aerospace, automotive, manufacturing, printing, publishing, and warehousing.

Various types of guidance systems are available, such as the laser, inertial, wire, and optical systems. The laser system uses retroreflective targets placed around a warehouse, reflecting a laser beam back to the forklift, allowing it to pinpoint its position. The inertial system operates using magnets embedded in the floor, with sensors on the forklift detecting these magnets to maintain its path. The wire system relies on antennas to track the forklift's position in relation to wires embedded within the warehouse floor, while optical systems utilize sensors to follow ultraviolet markings painted on the floor.

As the requirements for forklifts evolve, so does the technology behind their operation. Continue to the next page for further insights into forklifts and other related subjects.