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Data acquisition


Made for heavy lifting A


When Hyster-Yale Group, a manufacturer of heavy forklift trucks, needed to record and process a large quantity of data when testing its trucks, it turned to data acquisition equipment from HBM


ccelerated Pavement Testing can be defined as the “controlled application of wheel loading to pavement


structures for the purpose of simulating the effects of long-term in-service loading conditions in a compressed time period”. The Hyster-Yale Group (HYG) factory on


the industrial estate near the canal harbours in Nijmegen, Netherlands, manufactures Hyster heavy forklift trucks on two production lines. These trucks have been designed for lifting and moving heavy loads weighing from eight to 52 tonnes. The dynamic in sectors such as industry, transport and logistics makes the continuous development of new models necessary, with improvements in payload, lifting height, lifting speed, energy consumption, maintenance-friendliness and safety being the principal driving factors. Product development and validation occur entirely in house at Hyster. HBM supplies HYG with measuring sensors and data acquisition equipment for monitoring practical and endurance tests. Product development at Hyster in Nijmegen


takes place according to a fixed plan and is carefully recorded. The process is continually adapted in line with clients’ changing preferences, new working methods, new technology and new regulations. Every new model is developed in a full CAD/CAM environment and tested using simulations. The extent to which a new model can differ from existing ones can vary. It can be partly based on an existing model, with improvements to a number of crucial parts, or an almost entirely new model can be developed. The basic assumption in every case is that a new model has to go into series production, whereby the number made can vary. Over 2,000 trucks are built in Nijmegen every year, making Hyster the market leader in the heavy forklift truck segment. The company also produces client- specific solutions such as attachments for lifting specific loads.


PrototYPe A first prototype is built once the virtual design of a new model is complete and is 95 per cent ready for production. This prototype is subjected to extensive practical testing on the in-house test site. The forklift undergoes clearly-defined test cycles in order to validate the design, test the construction and the parts and measure its performance. Client input and feedback are included during this phase. More prototypes are built after the test phase and further development, and selected clients test


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them in practice for a number of months. A model is ready for series production in the Nijmegen factory only after these tests have been successfully completed. Two production lines are set up for assembling the trucks. One line is for the high-volume segment in a range from eight to 16 tonnes and the other is a low-volume line in which heavy models up to 52 tonnes are assembled. The first models off the line undergo extensive quality testing.


extensive test cYcle “We set very high requirements for the forklift trucks, because they are used in industrial environments for especially tough work”, explains test engineer Rob van den Brink. “Our latest prototype can lift two stacked sea containers. Aspects such as ride characteristics, turning circles, stability and lifting capacity are studied in simulations during the design phase. The practical tests are of crucial importance in


April 2019 Instrumentation Monthly


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