Evolutionary design
September 1st 2006

Narrow Aisle, a leading UK specialist materials handling equipment manufacturer, has introduced the latest version of its successful FLEXI articulated truck.

The FLEXI Generation 4 or G4 as the new model is known is an electric-powered truck and boasts all of the design features that have established the FLEXI as Europe's biggest selling articulated forklift, but includes a number of significant advances that will prove attractive to operators and specifiers alike.

Operator safety is a key consideration within any materials handling operation and the G4 includes a number of enhanced safety features. For example, an operator presence switch fitted within the seat prevents operation unless the driver is in the sitting position.

This eliminates the risk of situations where, for example, forklift operators who only want to move the truck forward a couple of metres are tempted to start the machine while standing alongside it and pushing the accelerator with their hand.

This kind of act, while going against health and safety legislation and, indeed, the laws of general common sense, is surprisingly common as any warehouse or distribution centre manager will testify.

By carrying out such an act, the driver runs several risks not the least of which is catching his or her foot under the wheel of the truck. By placing the operator presence switch within the seat, Narrow Aisle have ensured that the G4 is unable to move unless the operator is seated.

The presence switch system's sensors also prevent the mast from tilting, lifting or lowering unless the driver is sitting in the operating position

The G4's fully adjustable lumbar support seat has also been enhanced and is now cloth covered as standard for extra operator comfort within the warehousing environment.

Arm rests are available as an option.

A further safety advance on the G4 is the redesigned accelerator and brake layout.

FEM, the governing body of the European materials handling industry, recommends that the brake and accelerator pedals on any forklift truck should be biased towards the right to ensure a familiar 'automotive' type control arrangement for the operator.

The G4's automotive-style pedal layout complies with the directive and, in addition, the accelerator and brake pedals are now wider and fitted with rubber cushions. This means that the operator can use either foot to brake or accelerate safely and comfortably.

When the brake of the G4 is applied, it switches off the traction to ensure that the truck comes to a smooth, controlled stop every time and without excessive brake wear.

When working outside with FLEXI operators often need to stop and restart on an incline. The G4 features the newly developed Narrow Aisle Safe Start (NASSA) system which allows the operator to restart the truck and move off up an incline without any possibility of roll back.

If the truck is on an incline when it stops, the operator simply presses a button situated on the side of the steering column to reapply the traction for a few seconds and enable a smooth hill start to be made.

The overall size of the operator's cabin has been increased to provide greater room all-round and, therefore, more comfort over the period of a full shift, while a large access step and twin access handles combine to make getting on and off of the truck safer and less strenuous.

Within the cabin itself, the G4's controls are positioned as they would be on a conventional forklift truck. Furthermore, each lever is clearly identified so that the operator can quickly and easily familiarise him or herself with each hydraulic function.

This standardised layout is particularly important in the third party logistics industry where large numbers of temporary staff are often required to meet seasonal peaks.

The cabin features a fully enclosed storage compartment for the operator's personal belongings, while a cup holder is located behind the arm rest to reduce the risk of spills. In addition, the G4 features a newly developed a rear shelf on which the seemingly mandatory roll of shrinkwrap can be carried.

To make pallet entry and exit easier for the operator, the forks of the G4 have been redesigned and now feature a tapered profile. This small enhancement is likely to have a significant impact on the truck's productivity during the course of a typical eight-hour shift.

Mechanically, the G4 has also undergone some modifications. The truck's front wheel drive system which, when the truck is fully laden, provides extra traction is powered by a 9.6kW heavy duty motor for long service life, while the use of a high quality transverse axle gives continuous drive to both front wheels essential when 90 degree stacking operations are taking place.

With the growth in high bay warehouse development, the average lift height of the FLEXI has increased by 50% over the last three years. To ensure that the FLEXI continues to meet the highest standards of lift stability, the G4's articulation unit itself has been upgraded with an integrated rack and pinion hydraulic steering mechanism for smooth controlled stacking.

The G4 retains many of the awardwinning features that have helped to establish the FLEXI as Europe's best selling articulated truck.

The truck is powered by a heavy duty 48 volt battery. No chains or slings are required during battery change over operations the battery is removed simply and efficiently at low level from the rear using a hand pallet truck or another forklift.

This eliminates the risk of the battery being dropped from height and is another noteworthy safety feature of the FLEXI.

Because the battery is mounted low in the chassis, there are no moving parts below the battery compartment itself and therefore the battery does not need to be removed during routine maintenance and servicing operations. In fact the only time the battery has to be taken out is when it has to be changed during multi-shift operations. A quick release cover at the back of the truck gives access to the battery cells.

The G4's mast ensures safe and productive loading. It provides excellent visibility for the operator and, because it is mounted at wide centres, stability is ensured at all lift heights.

The operator's view is further enhanced by the two-post cantilever design of the G4's overhead guard. The guard's CE approved design features angled roof bars which not only offer unrivalled load and stacking visibility when lifting but also excellent all-round operator protection.

Peter Wooldridge, managing director of Narrow Aisle and a pioneer of the articulated truck concept, heads up the company's in-house design team. Peter comments: "We see the introduction of the G4 not as a revolution in articulated truck design but more the evolution of what is already a well established and highly successful product. The FLEXI continues to outsell its rivals because we constantly look to the future and the design developments we have made to the G4 will ensure that we maintain our market leading position."

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