Carlo Gavazzi Mobile Equipment Solutions

Solutions for Mobile Equipment

Carlo Gavazzi is a market leader in Sensors, Switches, and Controls with one of the broadest range of products in the industry. With over 90 years of automation experience, Carlo Gavazzi knows what it takes to manufacture products for tough environments and challenging applications. With local sales and distribution in over 100 countries, Carlo Gavazzi can support you locally around the world.

What's so tough about mobile equipment

Mobile equipment is one of the most challenging applications for a sensor. Any device installed on mobile machinery whether it's a garbage truck, mobile crane, concrete mixer, dump truck, tractor or fire truck, is subject to extreme operating conditions including continuous exposure to high levels of shock and vibration, wide temperature variations and voltage fluctuations, with voltage sags and peaks of up to 200 V, frequent high pressure and high temperature wash-down cycles and high electromagnetic interference. Carlo Gavazzi's ICS E1 rated inductive sensors are specifically designed with mobile equipment in mind.

What is an E1 Certified Sensor

E1 type approval is a rigorous government certification for mobile equipment that allows operation of a component on public roads and certifies it fully meets the extremely stringent requirements for use on mobile equipment. The specific challenges that are typically encountered on mobile equipment include:

Challenge Carlo Gavazzi Sensors
On mobile equipment, sensors must operate in very low ambient temperatures as well as very high operating temperatures (heat from engines and exhaust systems). Thanks to their special design, Carlo Gavazzi E1 sensors can operate continuously between -40°C to +85°C (-40° to +185°F).
Trucks periodically undergo high pressure and high temperature washdown to remove dirt, dust, salt, grease and oils accumulated during daily operation. Carlo Gavazzi E1 sensors have been designed with a special sealing and have a certified IP69K protection degree to avoid any water and moisture penetration during the washing cycles.
The power source in large vehicles is a conventional battery which is generally affected by very high fluctuations due to:
  • Voltage sags caused by discharging batteries
  • Increased voltage during charging
  • Voltage peaks generated by load switching, such as with hydraulic pumps
Our E1 sensors have a wide voltage supply range, from 8 to 60 VDC, to grant maximum operational safety with any vehicle battery condition.
Trucks are affected by very high electromagnetic interference to which industrial standard components would fail with expensive downtime or serious consequences on the vehicle safety. In particular, all forms of radio transmitters have the potential to interfere with electronic equipments. Our E1 sensors are immune to false actuations when exposed to field strengths of 200 V/m, our typical competitor can only withstand 100 V/m.
Interruption of inductive loads can cause a series of quick high frequency pulses, mainly caused by arcing (sparking), and very high voltage surges are generated. This phenomenon is known as contact bouncing. Our E1 sensors are qualified for burst immunity up to 4 kV according to EN 61000-4-4, certifying our sensor’s immunity to fast transients due to contactor and solenoid switching.
Harmful interference may occur in the circuitry of mobile machines when starting up the vehicle. Faults of this kind are typically caused by power control devices and lightning strikes. Our E1 sensors are tested according to EN 61000-4-5, certifying sensors can withstand these voltage surges.
Electrostatic interference and damage Our E1 sensors are tested for both Contact Discharge (a high-voltage potential of 8 kV is directly applied to the sensor housing) and Air Discharge (high-voltage potential of 8 kV is applied to a plate at a specific distance from the sensor) to 8 kV according to EN 61000-4-2.

Typical Applications

Garbage Trucks
Garbage Truck Sensors

Garbage trucks utilize proximity sensors in order to monitor the position of lift arms, forks, compaction cylinders and to ensure that doors and gates are in position and locked. A loose or corroded connection to the battery can result in over-voltages which can damage electronic circuits. CARLO GAVAZZI's E1 rated sensors are designed to survive these over-voltages.

In addition to sensing applications, CARLO GAVAZZI also offers monitoring relays for detecting high and low battery voltage, generator voltage and over/under current on generators supplying hydraulic pumps for operation of the lift arms and cylinders.

DC switching solid state relays can be used for disconnecting loads from the battery and for on/off control of fans on diesel engines.

Fire Trucks
Fire Truck Sensors

Fire trucks utilize proximity sensors to confirm the ladder position and the alignment of ladder rungs, position of the telescopic boom, position of the outriggers, and to confirm the storage compartment is closed. Communication devices such as radio-telephones can cause interference with standard inductive sensors. CARLO GAVAZZI's E1 rated sensors are designed to ignore these high strength fields.

In addition to sensing applications, CARLO GAVAZZI also offers monitoring relays for detecting high and low battery voltage, generator voltage and over/under current on generators supplying hydraulic pumps for operation of the lift arms and cylinders.

DC switching solid state relays can be used for disconnecting loads from the battery and for on/off control of fans on diesel engines.

Mobile Cranes
Mobile Crane Sensors

Mobile cranes utilize proximity sensors in order to monitor the position of the operator's cab, confirm if the telescopic boom is raised, monitor the position of the outriggers, and to ensure the doors are in place and locked. During the normal charging and discharging cycles of the battery, over-voltages which can damage electronic circuits are generated. CARLO GAVAZZI's E1 rated sensors are designed to survive these over-voltages.

In addition to sensing applications, CARLO GAVAZZI also offers monitoring relays for detecting high and low battery voltage, generator voltage and over/under current on generators supplying hydraulic pumps for operation of the lift arms and cylinders.

DC switching solid state relays can be used for disconnecting loads from the battery and for on/off control of fans on diesel engines.

Concrete Trucks
Concrete Truck Sensors

Cement trucks utilize proximity sensors in order to monitor the position of the discharge chute, the position of the charging hopper, and monitoring the rotation of the drum to ensure proper mixing of the cement. It is important to periodically clean the truck with a high pressure and temperature washdown in order to remove dirt, dust, and oils. These jets of water can damage tradional proximity sensors. CARLO GAVAZZI's E1 rated sensors are designed to withstand high pressure/temperature washdowns.

In addition to sensing applications, CARLO GAVAZZI also offers monitoring relays for detecting high and low battery voltage, generator voltage and over/under current on generators supplying hydraulic motors for the revolving drum.

DC switching solid state relays can be used for disconnecting loads from the battery and for on/off control of fans on diesel engines.

Excavators and Dump Trucks
Excavators Sensors

Excavators and dump trucks utilize proximity sensors in order to confirm the position of the arm, monitor the position of the operator's cab, confirm the storage compartment and cab door are closed, and monitor if the dump truck's bed is down. There have been many horror stories relating to drivers driving off with the truck bed raised and hitting overpasses and power lines. Sensors on dump trucks are subject to a great deal of mechanical vibration and shock that can destroy tradional proximity sensors. CARLO GAVAZZI's E1 rated sensors are designed to withstand the strong mechanical vibrations and shock.

In addition to sensing applications, CARLO GAVAZZI also offers monitoring relays for detecting high and low battery voltage, generator voltage and over/under current on generators supplying hydraulic pumps for operation of the lift arms and cylinders.

DC switching solid state relays can be used for disconnecting loads from the battery and for on/off control of fans on diesel engines.

Our Product Range for the Mobile Equipment Industry

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