Forklift Wire Guidance Systems
Boost safety and efficiency with warehouse wire guidance for VNA forklifts. Minimize rack and inventory damage, prevent collisions, and maximize space in your very narrow aisle (VNA) operation.
What is Wire Guidance?
Wire guidance is an advanced electromagnetic system that automates steering for VNA (Very Narrow Aisle) forklifts as they move through warehouse aisles. By embedding a charged wire in the floor, VNA forklifts can automatically stay centered—reducing the risk of rack damage, inventory loss, and collisions. This “hands-off” approach streamlines high-density warehouse operations, cuts costs, and improves safety.
- Maximize Aisle Space: Enable true very narrow aisle (VNA) layouts for high-density storage.
- Reduce Rack & Inventory Damage: Automated steering prevents costly accidents and repairs.
- Boost Productivity: Drivers focus on lifting and picking—not steering.
- Employee Safety: Fewer collisions mean fewer injuries and claims.
- Cost-Effective: Wire guidance pays for itself by minimizing damage and increasing throughput.
Guidance Methods Compared
Wire Guidance
- Electromagnetic wire embedded in floor
- Keeps forklifts perfectly centered
- Works best for long aisles, fewer forklifts
Rail Guidance
- Steel rails installed along aisle base
- Physical guide for forklifts
- Ideal for shorter aisles or high forklift volume
Cost & Installation
- Wire: ~$5/ft + electronics, install, cleanup
- Rail: ~$35/ft for both sides, plus removal/disposal
- Blueprint and expert install required for both
VNA Forklift Types
- Turret trucks (swing reach)
- Order selectors
- Wire-guided narrow aisle trucks
- Custom turret heads & advanced safety systems
Wire Guidance System Installation
Installing a wire guidance system requires precision. After blueprint review, installers cut a groove into the aisle floor, embed the active wire, and seal with epoxy. The system connects to a Line Driver Unit (LDU) that transmits the electromagnetic signal throughout the circuit. Each aisle is a closed loop, fully mapped for forklift control. UL certification ensures maximum safety and compliance.
- Plan Line Driver location and wire run length
- Calculate total aisles and required guides
- Cut, embed, and seal wire for a long-lasting system
- Test all VNA forklifts for seamless aisle control
- Meet all safety and UL compliance standards
How Wire Guidance Works
- Active wire installed in a groove down aisle centerline.
- Low-voltage RF signal sent from Line Driver Unit (LDU).
- Forklift sensor automatically centers and tracks the wire.
- No rails needed—perfect for long, straight aisles.
- Reduces human error and ensures repeatable travel paths.
Rail Guidance Pros & Cons
- Physical steel rails guard the rack base and columns.
- Two rails per aisle needed—one for each side.
- Best for facilities with frequent truck traffic.
- Higher install cost but simpler for very busy aisles.
- Still reduces rack damage and helps maintain tight aisles.
Wire vs. Rail Guidance Cost
- Wire guidance: ~$5/foot + cost for electronics and installation.
- Rail guidance: ~$35/foot (for both sides) plus install and removal/disposal.
- Wire guidance is more cost-effective for long aisles; rails better for short, busy aisles.
- Both systems require blueprint planning and professional installation.
Types of VNA Forklifts
- Turret trucks with rotating masts for both-sides picking.
- Order selectors for rapid batch picking.
- Custom turret heads, shuttle forks, advanced safety features.
- Energy-efficient designs and personal protection systems (PPS).
- Leading brands: Yale, Hyster, Raymond, Crown, Jungheinrich, Toyota, and more.