New Load Sensor Technology on Container Forklifts
As Vietnam’s logistics and seaport industries are growing at a rapid pace, pressure on container handling time is increasing significantly. However, speed cannot come at the expense of safety. Potential risks such as vehicle rollover due to overloading, incorrect load center positioning, or inaccurate determination of container weight (related to VGM regulations) remain major challenges for port and warehouse operators.
To address these issues, leading global forklift manufacturers (Kalmar, Konecranes, TCM, Mitsubishi, etc.) have integrated next-generation load sensor technology into reach stackers and heavy-duty forklifts. This is also a key technical standard that Samcovina places special emphasis on when importing and distributing forklifts in the Vietnamese market.
- What is a load sensor system on container forklifts?
Unlike traditional mechanical weighing devices, modern load sensing systems on container forklifts are sophisticated assemblies of electronic components.
Basically, the system operates using hydraulic pressure sensors mounted directly on the lifting cylinders, or load cells installed at pivot pins or on the container spreader frame.
Operating principle:
When the forklift performs a lifting operation, the hydraulic oil pressure or the tensile force on the lifting structure changes in proportion to the load weight. The sensors detect these physical changes, convert them into electronic signals, and transmit them to the central control unit (ECU). The data is then processed using complex algorithms to eliminate noise factors (such as vibrations during vehicle movement) and is displayed accurately in real time on the in-cab monitor.
Illustration of the operating principle of the load sensing system on a container forklift.
- Outstanding features of the new sensor technology
At Samcovina, we clearly see the difference in operational efficiency between older forklift models and newer ones equipped with this technology. Below are three core features:
- Overload warning and anti-tip system (LMI – Load Moment Indicator)
This is the most critical feature for ensuring operator safety and asset protection. On reach stackers, lifting capacity is not fixed but varies according to the load chart: the higher the lift height or the farther the boom outreach, the lower the allowable load.
The LMI system continuously calculates the tipping moment based on:
– Current container weight
– Boom angle
– Boom length
Intelligent protection mechanism:
When the forklift approaches the safe operating limit (e.g. 90% of allowable load), the system activates audible and visual warnings. If the operator attempts to exceed this limit, the system automatically interlocks dangerous operations such as lifting up or extending the boom, allowing only safe actions like retracting the boom or lowering the load to restore stability.
- High-accuracy cargo weighing (VGM verification support)
The new sensor technology on European forklifts supplied by Samcovina offers extremely low measurement error (typically under 1% or ±50 kg for containers weighing tens of tons).
This feature enables:
– Determination of the actual container weight immediately after lifting from the ground or trailer.
– Direct printing of weight tickets or wireless data transmission to terminal/warehouse management systems (TOS/WMS).
– Strict compliance with SOLAS regulations on Verified Gross Mass (VGM) without the need to drive the container through a static weighbridge, resulting in significant savings in time and fuel.
- Monitoring the “health” of the hydraulic system
Modern load sensors also function like a “doctor” for the machine. They help detect abnormalities such as sudden increases or drops in pressure (pressure spikes) within the lifting cylinders. This allows maintenance teams to predict potential failures of hydraulic pumps, seals, or control valves early, enabling proactive maintenance planning.
- Economic and operational benefits for enterprises
Investing in forklifts equipped with accurate load sensing systems delivers a high ROI (Return on Investment) thanks to the following factors:
– Optimized equipment lifespan: Completely prevents overloading—the leading cause of chassis cracks, hydraulic hose failures, and engine damage. This is especially important for used forklifts.
– Data transparency: For forklift rental companies or cargo handling service providers, the weighing system allows precise monitoring of handled tonnage, preventing fraud and disputes with customers.
– Enhanced professional image: Operating a fleet that meets international safety standards makes it easier for companies to bid for large logistics projects with stringent HSE (Health – Safety – Environment) requirements.
- Representative container forklift models and Samcovina services
As a specialist importer of equipment from G7 markets, Samcovina currently distributes various forklift models equipped with this technology:
– European brands (Kalmar, Konecranes, Linde): Renowned for intelligent electronic management systems, multi-point sensors, intuitive displays, and the highest accuracy levels.
– Japanese brands (TCM, Mitsubishi, Toyota): Sensor systems designed for durability, capable of withstanding harsh environments, and easy to maintain and repair.
Professional technical services:
In addition to supplying forklifts, Samcovina’s technical team also provides:
– LMI system inspection: Ensuring that load sensors on imported forklifts (including used units) operate accurately before handover.
– Installation and retrofit: Upgrading electronic weighing systems and overload warning devices for older models not originally equipped.
– Calibration: Periodic calibration to ensure measurement errors always remain within acceptable limits.
