Sensor solutions for material handling equipment

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Boost your machine performance and solve your challenges

The shortage of qualified operators calls for a higher level of automation and operator assistance functions. High-performance sensors help increase productivity and process flexibility. The material handling industry always needs reliable, high-performance sensor solutions.

Choosing the most suitable sensor solution is the key to reliably advancing the right sensor solution. We guide you toward the right sensor solution for material handling application areas such as static stability control, load monitoring, and fluid management. These application areas can be found on aerial work platforms, scissor lifts, loader cranes, mobile cranes, telehandlers, tower cranes, and many other different machines.

Sensor Solutions Guide

Baumer sensors give you the feedback you need to determine position, angle, inclination, and flex, helping you manage boom vibrations and deliver people and material where they need to be. Strain measurements are used to determine the mechanical load on vehicles. Fluid monitoring with temperature, pressure, and level sensors ensures reliable hydraulic system operation.

Overview of sensor solutions for applications on material handling equipment:

Overview of sensor positions on material handling equipment

Boom angle positioning

Boom angle positioning provides the information needed to calculate the working range and vehicle stability.

Thanks to robust magnetic sensing, a redundant 2-channel architecture, and PLd-compliant firmware, the EAM580R can be used in applications up to PLd per ISO 13849.

Vehicle leveling

Vehicle leveling provides essential information for stability control. With precise measurement results across the entire operating temperature range, the Baumer GIM600R inclination sensor boosts machine performance. Developed specifically for mobile machinery, this sensor solution has proven its reliability in demanding long-term tests and increases machine availability. It complies with the latest safety standard, ISO 13849-1:2023.

Outrigger positioning

Linear outrigger positioning is a mandatory input for working range calculation and vehicle stability control.

Thanks to its compact, rugged 3-chamber design, the GCA5 is ideal for outrigger integration and positioning measurement up to 7.8 m.

Robust magnetic sensing, a 2-channel architecture, and a redundant CANopen interface allow for easy system integration.

Load measurement

Load monitoring is required on many mobile machines that carry loads with operators on board, such as telehandlers. Such loads must be monitored during operation to prevent vehicle overload and tipping. Load monitoring thereby increases vehicle stability and operator safety.

Baumer strain sensors offer easily integrated measurement of large forces in demanding outdoor environments, delivering stable measurement despite changes in time and temperature. A single sensor can be used for different applications and force ranges.

They integrate easily into existing structures and can boost productivity through better use of equipment.

Home position detection

Boom positioning provides the information needed to calculate the working range and vehicle stability. The home position of the boom is monitored once the vehicle has finished work and is about to move.

Inductive proximity switches enable robust, non-contact measurement on off-highway vehicles.

Boom extension

Inductive proximity switches enable robust, non-contact measurement on off-highway vehicles.

Boom extension

Extended boom positioning provides the information needed to calculate the working range and vehicle stability.

Thanks to robust magnetic sensing, a redundant 2-channel architecture, and PLd-compliant firmware, the EAM580R can be used in applications up to PLd per ISO 13849.

Hydraulic pressure monitoring

The pressure of a fluid is one of the most important parameters in fluid technology. Its main purpose is to monitor operation and provide feedback control for work processes.

The fully welded Baumer pressure sensor, with high burst pressure capacity and durability, is ideal for hydraulic pressure monitoring.

Hydraulic oil level

Baumer's oil level switch prevents damage caused by low fluid levels. Baumer brings capacitive frequency-sweep technology to the off-highway industry. The CFAK 22 outperforms established technologies such as float switches, fixed-frequency capacitive sensors, and electro-optical level sensors. It is factory pre-set for hydraulic fluids and other operating fluids with similar properties, such as diesel and gearbox oil.

It can be used for non-pressurized fluid monitoring and leak detection in differential housings, gearboxes, and fluid tanks.

Application Areas

Static stability control

Static stability control refers to a proportional system that recalculates and defines the working range and vehicle stability based on sensor data — smart Baumer sensors for safe vehicle stability.

Load monitoring

Load monitoring is required on many mobile machines that carry loads while operators are present. Loads must be monitored during operation to prevent vehicle overload and tipping. Load monitoring increases vehicle stability and operator safety.

Hydraulic fluid monitoring

The hydraulic system is one of the key systems in modern mobile machinery. Knowing parameters such as temperature, viscosity, pressure, low fluid level, or leaks helps sustain productivity and prevent damage.

Static Stability Control

Static stability control refers to a proportional system that recalculates the working range and vehicle stability based on sensor data. Smart Baumer sensors for safe vehicle stability.

Outrigger positioning

Linear outrigger positioning is a mandatory input for working range calculation and vehicle stability.

Thanks to its compact, rugged 3-chamber design, the GCA5 is ideal for outrigger integration and positioning measurement up to 7.8 m.

Robust magnetic sensing, a 2-channel architecture, and a redundant CANopen interface allow for easy system integration.

Vehicle leveling

Vehicle leveling provides essential information for stability control. With precise measurement results across the entire operating temperature range, the Baumer GIM600R inclination sensor delivers accurate results and boosts machine performance. Developed specifically for mobile machinery, this sensor solution has proven its reliability in demanding long-term tests and increases machine availability. It complies with the latest safety standard, ISO 13849-1:2023.

EAM580RS – Safety-Certified Absolute Encoder

Boom rotation positioning

Boom rotation positioning is an important metric for calculating the working range and for stability control.

Thanks to robust magnetic sensing, a redundant 2-channel architecture, and PLd-compliant firmware, the EAM580R can be applied up to PLd per ISO 13849.

Boom angle positioning

Boom angle positioning provides the information needed to calculate the working range and vehicle stability.

Thanks to robust magnetic sensing, a redundant 2-channel architecture, and PLd-compliant firmware, the EAM580R can be used in applications up to PLd per ISO 13849.

Boom load monitoring

Boom load monitoring is required on aerial work platforms that carry loads and have machine operators on board. These loads must be monitored during operation to prevent vehicle overload and tipping. Boom load monitoring thereby increases vehicle stability and operator safety.

The fully welded Baumer pressure sensor, with high burst pressure capacity and durability, is ideal for hydraulic-pressure-based load monitoring.

Boom extension

Extended boom positioning is a mandatory input for working range calculation and vehicle stability. Thanks to its compact, rugged 3-chamber design, the GCA5 is ideal for outrigger integration and positioning measurement up to 7.8 m.

Robust magnetic sensing, a 2-channel architecture, and a redundant CANopen interface allow for easy system integration.

Basket load monitoring

Load monitoring is required on many mobile machines that carry loads with operators on board. Such loads must be monitored during operation to prevent vehicle overload and tipping. Load monitoring thereby increases vehicle stability and operator safety.

They integrate easily into existing structures and can boost productivity through better use of equipment.

Load Monitoring

Outrigger load monitoring

Monitoring outrigger load with pressure sensors on the hydraulic cylinder is an option for monitoring boom load, basket load, and vehicle leveling.

Such loads must be monitored during operation to prevent vehicle overload and tipping. Load monitoring thereby increases vehicle stability and operator safety.

The fully welded Baumer pressure sensor, with high burst pressure capacity and durability, is ideal for hydraulic pressure monitoring.

Boom load monitoring

The fully welded Baumer pressure sensor, with high burst pressure capacity and durability, is ideal for hydraulic-pressure-based load monitoring.

Boom load monitoring

Boom load monitoring with strain sensors describes the indirect measurement of material deformation in the boom to determine boom load.

Such loads must be monitored during operation to prevent vehicle overload and tipping. Load monitoring thereby increases vehicle stability and operator safety.

The DST55R is a rugged strain sensor for demanding outdoor use.

Load monitoring

Loads must be monitored during operation to prevent vehicle overload and tipping. Load monitoring thereby increases vehicle stability and operator safety.

The DST55R is a rugged strain sensor for demanding outdoor use.

Hydraulic Fluid Monitoring

Hydraulic pressure monitoring

The pressure of a fluid is one of the most important parameters in fluid technology. Its main purpose is to monitor operation and provide feedback control for work processes.

The fully welded Baumer pressure sensor, with high burst pressure capacity and durability, is ideal for hydraulic pressure monitoring.

Hydraulic oil temperature

It is important to know the hydraulic oil temperature in a system. Excessively high temperatures cause premature aging of hydraulic fluid and seals. In addition, fluid viscosity depends on temperature, and control may need to be adjusted for fluid temperature.

Its compact, rugged design offers typical process connections such as G ¼ A ISO 1179-2 (DIN 3852-E). It is ideal for low-pressure conditions (up to 100 bar).

Hydraulic oil level

It can be used for non-pressurized fluid monitoring and leak detection in differential housings, gearboxes, and fluid tanks.

Make a Difference

Make a difference with your material handling equipment

Rising labor costs are accelerating the trend toward more automation, process flexibility, and performance in material handling equipment. In addition, the changing regulatory environment is increasing demand for sensors in safety applications.

Discover how you can achieve these goals and make a difference with Baumer sensors.

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Our expert engineers are ready to help you identify the most suitable solution for your industry.

Sensor solutions for material handling equipment

Boost your machine performance and solve your challenges

Overview of sensor solutions for applications on material handling equipment:

EAM580R – Absolute Encoder

GIM600R – Inclination Sensor

GCA5 – Cable Transducer

DST55R – Strain Sensor

IR12V.P – Inductive Proximity Switch

GCA5 – Cable Transducer

EAM580R – Absolute Encoder

PP20S – Pressure Sensor

CFAK22 – Oil Level Switch

Static stability control

Load monitoring

Hydraulic fluid monitoring

GCA5 – Cable Transducer

GIM600R – Inclination Sensor

EAM580RS – Safety-Certified Absolute Encoder

EAM580R – Absolute Encoder

PP20S – Pressure Sensor

GCA5 – Cable Transducer

DST55R – Strain Sensor

PP20S – Pressure Sensor

PP20S – Pressure Sensor

DST55R – Strain Sensor

DST55R – Strain Sensor

PP20S – Pressure Sensor

TE2 – Compact RTD Temperature Sensor

CFAK22 – Oil Level Switch

Make a difference with your material handling equipment

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Sensors for agricultural equipment

Sensors for commercial vehicles

Mobile Machinery Sensor Portfolio

Have a Sector-Specific Question?

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