Bridging multiple production levels often creates a severe bottleneck when heavy pallets or specialized containers must be manually staged and loaded onto a standard lift. Gradin designs and manufactures Heavy Duty Telescopic Fork VRCs that completely bypass this limitation by actively reaching into storage racks or adjacent conveyor lines to retrieve and deposit loads autonomously. Rather than offering a one-size-fits-all solution, we custom-engineer the fork stroke length, lateral spacing, and structural payload capacity of every vertical reciprocating conveyor to match your facility’s exact aisle clearances and container dimensions. By tying directly into your AS/RS or plant-wide robotic controls, these units eliminate the need for intermediate forklift transfers between floors, ensuring a high-throughput, continuous flow of heavy materials across multi-tier manufacturing environments.
| Technical Category | Key Parameters | Standard Reference | Gradin Bespoke Options (ETO) |
| I. Core Performance | Rated Payload Capacity | 5,000 kg (5 Tons) | Scalable up to 150,000kg (150T+) |
| Vertical Travel (Stroke) | 6,000 mm | Variable travel up to 30,000 mm+ | |
| Fork Reaching Stroke | Single Deep | Double/Triple Deep / Bespoke Extension | |
| Positioning Accuracy | ± 5 mm | Millimeter-Level Calibration (± 1 mm) | |
| II. Structural & Material | Mast Engineering | Double/Quadruple Rail | FEA-Optimized High-Rigidity Alloy Steel |
| Fork Technology | Fixed Reach | Servo-Driven High-Speed Telescopic Forks | |
| Lift Drive System | Hydraulic / Traction | Synchronized Gear-Motor / Servo Drive | |
| Surface Treatment | Industrial Powder Coat | Anti-Static / Cold-Storage Grade / Stainless | |
| III. Control & Intelligence | Control System (PLC) | Siemens S7-1200 | Siemens S7-1500 / Allen Bradley / 5G |
| Communication Protocol | Industrial Wi-Fi | Profinet / EtherCAT / TCP-IP Integration | |
| System Connectivity | Standalone | Full WMS / MES / Industry 4.0 Integration | |
| Feedback Mechanism | Limit Switches | Absolute Encoders / Laser Rangefinders | |
| IV. Environment & Safety | Operating Temperature | -10°C to +40°C | Extreme Cold (-30°C) or Foundry Grade |
| Safety Gates | Manual / Semi-Auto | Fully Automated High-Speed Power Gates | |
| Emergency Measures | Anti-Fall Gears | Anti-Burst Safety Valves / Redundant Power | |
| Compliance Standard | CE / ISO 9001 | Full OSHA / ASME / AS3000 Compliance |
FEA-Validated Structural Integrity for Extreme Bending Moments
Lifting a 100-ton load vertically is a standard engineering task, but extending that same load 2 meters into a storage rack creates a massive Bending Moment that standard lifts cannot withstand. Every Gradin Bespoke Telescopic Fork VRC undergoes rigorous Finite Element Analysis (FEA) during the design phase to simulate these eccentric loading profiles.
Zero-Deflection Masts: We utilize reinforced high-tensile box-section steel engineered to maintain absolute structural rigidity at heights up to 30 meters.
High-Tension Fork Assemblies: Our telescopic mechanisms utilize induction-hardened alloys and precision-ground slides to prevent sagging at full reach.
Dynamic Stability Control: This engineering-first approach ensures the system maintains absolute structural safety during high-speed transitions, protecting both your cargo and the integrity of your racking infrastructure.
Precision Synchronization and Millimeter-Perfect Reaching Logic
In modern automated warehousing (AS/RS), throughput is defined by docking speed and positioning accuracy. The Gradin Bespoke Telescopic Fork VRC utilizes advanced synchronized drive technology combined with closed-loop feedback.
Synchronized Motion Control: Utilizing Siemens S7-1500 PLC logic, the VRC achieves perfectly smooth vertical-to-horizontal transitions, eliminating the “bounce” or jerk found in standard goods lifts.
Millimeter Accuracy: High-resolution absolute encoders and laser distance sensors ensure the forks align with the rack opening with an accuracy of ±1mm.
Servo-Driven Reach: Our telescopic forks are powered by high-torque servo motors, providing a soft-start/soft-stop reaching profile that protects sensitive electronics or high-value cargo from inertial shock during the retrieval process.
Industry 4.0 Connectivity and Automated Factory Integration
Vertical logistics must function as a transparent node within your digital material flow. Every Gradin Bespoke Telescopic Fork VRC features an open-architecture control system designed for full factory integration.
Real-Time WMS Handshake: Through Profinet, EtherCAT, or 5G connectivity, the VRC communicates directly with your Warehouse Management System, receiving missions and reporting load status in real-time.
Autonomous Operational Logic: The system can be programmed to autonomously manage pallet retrieval, sequencing, and buffering without human intervention, turning vertical space into a dynamic material artery.
Predictive Maintenance Monitoring: The system tracks chain tension, motor torque profiles, and cycle health, providing the data needed to prevent unplanned downtime in high-stakes 24/7 automated facilities.
[E-commerce & 3PL] – High-Density Vertical AS/RS Integration
The Challenge: Maximizing storage density in high-ceiling warehouses where rapid pallet retrieval is critical for order fulfillment speed.
Gradin Solution: The Gradin Telescopic Fork VRC acts as the high-speed vertical link within your automated storage and retrieval system. With multi-deep reaching capabilities, it allows for high-density racking configurations, significantly reducing the facility’s footprint while increasing total pallet throughput.
[Automotive Stamping] – Heavy Die Storage and Management
The Challenge: Retrieving 50-ton stamping dies from multi-level storage racks and delivering them precisely to AGVs or press bolsters.
Gradin Solution: Our Bespoke Heavy-Duty VRCs provide a high-capacity vertical artery. By delivering dies directly into the rack with millimeter precision, the system eliminates manual crane risks and reduces tool-change intervals in high-output automotive press shops.
[Cold Storage & Pharma] – Temperature-Controlled Vertical Material Flow
The Challenge: Operating automated vertical logistics in -30°C environments where standard hydraulic seals and sensors frequently fail.
Gradin Solution: We customize these units with low-temperature alloy steel and specialized lubricants. The integrated control logic and automated telescopic reaching turn a dangerous manual task into a synchronized, automated material flow within the cold-chain envelope, ensuring material integrity.
Redundant Safety Architecture and Precision Motion Monitoring
Safety in high-tonnage, high-reach automated logistics is our most critical engineering priority.
Active Anti-Fall Redundancy: Every Gradin Bespoke Telescopic Fork VRC is integrated with redundant mechanical anti-fall gears and hydraulic velocity fuses that lock the carriage instantly if any failure is detected.
Intelligent Reach Protection: The PLC features active collision-avoidance logic, using laser sensors to verify the rack path is clear before forks are extended, ensuring no structural damage occurs during automated cycles.
Interlocked Safety Enclosures: We provide synchronized high-speed power gates that perform a digital handshake with the VRC, ensuring that vertical transitions are fully isolated from personnel, meeting the most stringent global safety ratings (ISO 13849/CE).
For this heavy-duty series, we can engineer load capacities up to [300] tons, with platform dimensions and lifting heights customized to your operational envelope. Requirements exceeding our standard engineering matrix will undergo a Finite Element Analysis (FEA) by our engineering team to ensure structural viability before proposing a solution.
To initiate the engineering proposal, please provide the following baseline data:
Rated Load Capacity
Maximum Lifting Height & Closed Height
Platform Dimensions (L x W)
Duty Cycle (e.g., operational cycles per hour/day)
Environmental Conditions (e.g., indoor/outdoor, washdown, explosion-proof)
Pit depth or overhead clearance constraints
Yes. The control systems can be equipped with standard communication protocols (e.g., Profinet, Modbus, Ethernet/IP) utilizing [Siemens / Allen-Bradley / Omron] PLCs. This ensures seamless I/O signal synchronization with upstream/downstream conveyors, AGV/AMR units, and your central control room.
Every custom unit undergoes a mandatory Factory Acceptance Test (FAT) prior to dispatch. This includes continuous operational testing at 100% rated load, static overload testing at [120% / 125%] capacity, and the physical triggering of all mechanical anti-fall and hydraulic safety interlocks. FAT documentation and video proof are included in your engineering package.
Upon final approval of the General Arrangement (GA) drawings, the manufacturing lead time is typically 4 to 8 weeks. Oversized structural components are engineered with a modular design to fit into standard shipping containers (20FT/40HQ). On-site assembly utilizes pre-engineered bolted flange connections and heavy-duty aviation plugs, strictly eliminating the need for field welding.
We provide a standard [12/24]-month warranty covering the structural frame and primary hydraulic/electrical components. To minimize operational downtime, a comprehensive set of standard consumables (e.g., cylinder seal kits, travel switches, relays) is shipped alongside your equipment. During the warranty period, replacement parts for non-human-induced failures are dispatched via priority air freight (DHL/FedEx) within 48 hours.
Beyond the warranty, we guarantee lifetime engineering support. Your custom equipment's CAD drawings, electrical schematics, and BOM (Bill of Materials) are permanently archived in our system. This ensures you receive uninterrupted remote troubleshooting, maintenance guidance, and exact spare parts matching for the entire lifecycle of the equipment.
Gradin Machinery is a leading manufacturer specializing in aerial work platforms and hydraulic lifting solutions. With ISO & CE certifications, we provide safe, reliable, and customized equipment for global industrial needs
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