Case Study - Forklift

The Customer

An India-headquartered group of companies having 15 business lines. A highly trusted, more than a century old brand. Serving industrial material handling needs as India’s largest manufacturer of lift trucks.

THE PROBLEM

  • Needed a solution to:
    • Automate safety and maintenance checks at the start of day, and during operation of the forklift
    • Take on international competition in one of the largest growing markets

THE ANALYSIS

  • Needed to replace the existing analog cluster with a digital one
  • Add sensors and automate the process of sensing
  • Establish remote connectivity
  • Solution had to be designed for OEM and retrofit use

THE SOLUTION

  • Identified and located sensors to be added to the forklift
  • Designed a module to read sensor data and send data over GPRS using the MQTT protocol
  • Designed dashboard module with a rich graphics UI and an intuitive smart LED indicator to signal the instantaneous status of the forklift
  • Designed a rugged electronic digital cluster to work in stringent operating conditions

THE OUTCOME

  • Maintained market leadership
  • Ownership of electronics
  • Keeping products relevant

Technology Areas

  • Digital Cluster Retrofit Add-on
  • Machine Connectivity
  • Remote Monitoring
  • Fault Prevention & Analysis
  • Wireless Connectivity through MQTT
  • Third party Software Integration

TECHNICAL DETAILS

Forklift

Hardware

  • Single board module – double sided PTH
  • Add on GSM board – double sided PTH
  • Schematics, BOM, Layouts & Gerbers: PADS from Mentor Graphics
  • Microchip PIC32 series Microcontroller
  • Kyocera 3.5”, 320x 3 x 240 resolution, color, graphics, TFT LCD
  • SIM800C GPRS module
  • Automotive grade power supply

Firmware

  • Code in C
  • IDE: MPLAB X
  • Graphics Screen Design – MPLAB Harmony Configurator

Cloud

  • MQTT broker interface

PROTOTYPE PHOTOGRAPHS

Get in touch with us