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In modern intralogistics, reliable recording of weight, volume, and load status is crucial for safety, efficiency, and cost-effectiveness. AKL-tec GmbH and VETTER Industrie GmbH have jointly developed a system that records these parameters directly on the forklift in real time and while driving. The sensor and software platform developed by AKL-tec thus makes the “dark side of freight” visible and creates new process standards in goods handling.

The cooperation between AKL-tec and VETTER began in 2022 as part of a government-funded research project with the Technical University of Munich. “Our goal was to develop a mobile, retrofittable system for forklifts to directly record weight, volume, weight distribution, and damage,” explains AKL-tec Managing Director Rüdiger Elben. This is because in many places in the logistics supply chain, this data is still determined manually or stationary – often in separate work steps, which slows down processes and makes them prone to errors. Added to this is the risk of undetected damage or incorrect load distribution, which further impairs the flow of materials.

As a result of this collaboration, the two specialist companies now offer a solution that combines load measurement, volume detection, and damage detection in a single step. This is made possible by combining VETTER's SmartFork technology with AKL-tec's expertise in sensor technology, image processing, and software. During transport, the intelligent fork automatically records all relevant data without interrupting the material flow. Manual measurements and stationary checks are no longer necessary.

While VETTER developed the load measurement system based on special sensors in the fork, AKL-tec took over the design and mechanics of the extendable camera unit, developed a rearview camera for the blind spot, and realized the complete fusion of all sensor data into a uniform system image that can be evaluated in real time. “We wanted to create an all-in-one system that combines previously separate work steps and at the same time increases work safety,” explains Dipl.-Ing. Tobias Weyl, Head of Business Development at VETTER. “The result shows what is possible when specialists from different disciplines work closely together.”

The measurement and image data processed by AKL-tec can be linked directly to merchandise management and logistics systems, opening up new possibilities for automation in material flow. AKL-tec and VETTER see the project as a starting point for further joint developments in Intralogistics 4.0.