Mar/April 2009

Computers for mounting on fork-lift trucks are getting smarter, smaller and more versatile. Sharon Clancy finds they are leading a productivity drive

Fork-lift trucks are in the front line when it comes to keeping stock on the move in the warehouse, but do you see them as simple workhorses, or instruments for driving productivity improvements?

If you're productivity-minded, then you probably already know it's the truck-mounted computers carried by these vehicles that hold the key to much of their potential for making improvements. Not only can these devices play a major role in streamlining your operations; they can also aid asset management and facilitate the deployment of RFID.

The sheer variety, both in the size of vehicle on which these devices are mounted and in the tasks they have to handle, means that you can't necessarily expect a one-size-fits-all philosophy here. Although this is quite a niche market in terms of unit volumes sold, the manufacturers have had to develop a range of models to suit these different operations.

 

Not that the idea of standardising on one model is ruled out. But if you're considering using a single model of truck-mounted computer across all your warehouse trucks, you need to take into account how they are going to be fixed to the truck.

'Check that the brackets permit you to put the computer in the optimum place on any of your trucks,' advises Ian Davies, managing director of LXE. 'Also, with many forklifts now leased especially for peak periods, do check that mounting brackets can be easily removed and do not damage the truck.'

Truck mounts have become so versatile, it is no longer simply a question of choosing a truck-mounted computer rugged enough to cope – although that remains a key factor, of course. 'With fork-lift truck mounted computers, it is critical to think about how the work is done in the warehouse,' says Davies.

'Different parts of the warehouse operation might require computers with different screen sizes, different methods of entering data (via touchscreen or keyboards, perhaps), or voice capability.'

Battery capacity comes into the equation if the computer is removed regularly from the truck. Some forklifts go in and out of warehouses, so visibility in poor light and bright sunlight may be important too.

Shocks and vibrations are a routine part of daily life on a forklift truck; and that means ruggedness is not only desirable, it is essential if a computer terminal is to survive the type of relentless pounding they get in this environment.

Like most rugged computers, vehicle-mount terminals will be put through the MIL-STD 810F test for ability to withstand shocks. It pays to ask the question, however, whether the test was done with the unit turned on, or if it was turned on after the test.

Screens are particularly vulnerable to shock and vibration damage. Some manufacturers such as LXE opt for a glass TFT screen for improved resistance to cracking and scratching, while other manufacturers prefer polycarbonate screens. Intermec's CV30 and CV60 computers have screens that are replaceable on site. The touchscreens on Datalogic's new R-series computers have what the company calls '2-tail' technology to protect the display from abuse.

The truck type also influences the choice of screen size. Early forklift terminals had 10in or 12in screens, mounted inside the cab's upright stanchion. Manufacturers have now introduced smaller-format vehicle-mounted computers with 6in or 7in screens, suitable for narrow-aisle trucks and powered pedestrian trucks.

Larger computers can protrude outside the truck cab, not only making them more vulnerable to damage, but also posing a safety hazard if they intrude into the driver's forward vision.

'There is greater awareness now that good forward vision is critical for safety in the warehouse and yard,' says Davies. 'Drivers need to be able to see potential hazards.' LXE's VX9, like various other modern truckmounts, has a feature that allows the driver to blank the screen when manoeuvring to avoid distraction.

Datalogic's R-series is offered with three screen sizes – 7in, 10in and 12in – all housed in an aluminium casing.

A smaller size need not mean a reduction in usability. ZetesIND's Quadrino vehicle-mounted computers, for example, might have only a quarter-size VGA screen, but this is brighter than usual, so visibility should not be impaired. The screen can be positioned horizontally or vertically within the casing, helping the Quadrino to fit into the smallest space.

Adopting smaller-format computers doesn't mean compromising on ruggedness either, or indeed on performance. Intermec's CV30 6.1in truck-mount has the same cast magnesium housing and IP66 rating as its bigger CV60 brother, along with a solid-state memory and heated screen.

Psion Teklogix's 8515 and LXE's VX3X units both have tough polycarbonate casings to absorb impacts. Backlighting makes data easier to read, even in poor or bright-light conditions, and the switch to a colour display of course helps too. The 8515 screen has an anti-reflective anti-glare coating.

Dumb or smart

Truck-mounted computers can operate as dumb terminals or fully functioning mobile computers, depending on whether they are communicating with legacy WMS systems or a state-of-the-art ERP system such as SAP.

To some extent computers with the Embedded Windows XP operating system, such as Psion Teklogix's 8580 and 8590 models, are supplanting those using Microsoft Windows CE.NET, long favoured by developers. IT departments like using XP because it reduces support costs (with XP they are likely to dealing with a single operating system company-wide).

It's cold inside

Many truck-mounted computers are used in freezer stores and outdoors in cold ambient conditions, so low-temperature performance and resistance to water and dirt ingress can also be key performance criteria.

It probably goes without saying that computers intended to be used continually in freezer environments should have as tough a freezer spec as the business can afford. 'Unless a computer is built to freezer specification, the screen will fog, and frost will build up, so check the environmental ratings,' warns LXE's Ian Davies. Some manufacturers seal the unit to make it airtight, and LXE goes a step further, coating the circuit board in silica to prevent moisture ingress.

Psion Teklogix's 8580 and 8590 have integrated heating for low-temperature operations. 'You have to build in this level of ruggedness from the start by using the right components,' says managing director Paul Westmoreland. 'It's not something you can add on later'. Intermec's CV30 and CV60 both have heated screens as standard.

Touchscreens are more user-friendly when it comes to inputting data than models that require use of a keyboard with a gloved hand.

Future-proofing

Vehicle-mounted computers tend to have long in-service lives, so it pays to ensure that there are enough communications options to handle future needs. Voice-directed picking, for example, can have a lot of appeal for warehouse operations. Some terminals are enabled for Voice-over-IP communication. Some can have headsets attached, either by cable or via a Bluetooth wireless connection. VoIP is built into all LXE computers, and is standard on some Psion Teklogix models including the 8515.

RFID is taking longer to have an impact on the supply chain, but can deliver cost benefits in some warehousing operations. RFID readers on forks, for example, can automatically capture weight data from pallets. Intermec has been an RFID pioneer, so it's no surprise that is CV30 truck-mounted computer can be integrated with the company's vehicle-mounted IV7 RFID reader.