Assistance systems in industrial trucks

An assistance system is a technical, often fully automated solution that supports machine operators in carrying out their logistical tasks. It can provide important information and assistance, as well as fully automated intervention when needed. These systems are increasingly based on artificial intelligence, enhancing safety and boosting productivity in everyday material-handling operations.

Digital helpers are everywhere. Drivers know them well: it beeps when reversing, it beeps when moving forward, and if we ignore it—because the warning threshold is set quite low—the onboard computer may even trigger emergency braking. That can be annoying. On the other hand, adaptive cornering lights, adaptive cruise control, and many other assistance systems are genuinely useful enhancements.

Industrial trucks have long been equipped with a wide range of digital assistance systems. In practice, legal requirements vary by country, industry, and application. As with any new business investment, it’s important to determine what is necessary, helpful, and productive—and what is not.
For example: The owner of a small company employs three forklift drivers and has three forklifts. When buying a new truck, he chooses a model with PIN-code access because all individual seat and steering-wheel settings are saved and automatically adjusted for each driver. This means he no longer needs to set everything manually. However, he hardly ever drives a forklift himself, and his three drivers do not normally switch machines during day-to-day operations. Economically speaking, it’s not essential, but it’s a nice feature to have. Profitability isn’t always the only factor.

Key assistance systems that prevent accidents and increase productivity

• Adaptive cruise control reduces speed in curves, on uneven surfaces, or when carrying heavy loads.
• Stability and tilt-warning systems detect potentially dangerous tipping angles before the truck becomes unstable and warn the driver in time.
• Front and rear cameras or mirror-assist systems improve visibility, especially to the rear and in narrow aisles.
• Lift and load monitoring uses sensors to check load weight, center of gravity, and fork position, issuing warnings when capacity limits are exceeded.
• Load stabilization and mast-tilt adjustment enable safe depositing, tilting, and lowering of loads—even on uneven ground—and reduce mast sway at height.

• Automatic fork positioning with laser sensors allows precise pallet handling while preventing cargo damage.
• Pre-set driving modes, similar to those in cars, provide added safety for beginners or full performance for experienced operators, depending on the task.
• Sensorimotor controls adapt to the driver’s handling style; the system responds sensitively to steering movements and lever pressure, making operation more intuitive (steering, acceleration).
• Automatic ramp-hold prevents the truck from rolling backward on inclines as soon as the accelerator pedal is released—the driver can simply step off; when they return and accelerate, the brake releases automatically.

• PIN-code and other key systems prevent unauthorized use and automatically apply each driver’s stored preferences.
• Adaptive load-distribution and gripping-angle systems adjust gripping and lifting angles to the size of the load.
• GPS and navigation systems optimize routes in outdoor areas and large indoor environments, reducing travel times.

Systems with limited benefit (gimmicks)

• Too many cameras or sensors without meaningful application distract more than they contribute to safety.
• LED “light shows”—too many rear or side warning lights—reduce safety benefits because they distract more than they warn.
• Complex network integrations without clearly defined operational processes create more cost than benefit and increase maintenance requirements.

Practical tips for new purchases

• Create a checklist with your drivers outlining 5–10 aspects of the current forklift that could be improved. Then review how often these issues occur. Ask your forklift or warehouse-technology supplier for a quote including the relevant assistance systems. Compare costs and benefits—remember that ergonomic workstations often reduce sick days and increase motivation, which boosts performance.
• Safety first: choose systems that demonstrably reduce risks (anti-tip, collision-avoidance, and load-warning systems).
• Check compatibility: systems should suit your load types, pallets, warehouse layout, and existing fleet.
• Training: assistance systems are only effective when drivers recognize and accept them as useful. This also requires regular updates and proper training.

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