FADA ENGINEERING

5 TON ELECTRIC TUGGER

FADA developed a 5-ton electric tugger with ±90° turning capability for safe and efficient die handling in the automotive sector. Designed for narrow factory aisles and operator-controlled precision, this battery-powered system reduces crane dependency and increases intralogistics efficiency.


5 TON ELECTRIC TUGGER

5 TON ELECTRIC TUGGER FOR AUTOMOTIVE DIE HANDLING

Project Summary

Challenges

  • Moving heavy dies safely from production lines to the storage area without crane dependency.
  • Operating in narrow corridors and intersections requiring ±90° turning and precise maneuvering.
  • Maintaining load stability and operator visibility during frequent start/stop cycles.

Our Solution

  • Designed a 5-ton operator-controlled electric tugger with compact chassis and tight turning capability (±90°).
  • Integrated proportional drive & braking, anti-rollback and creep-speed modes for safe positioning under dies and racks.
  • Added safety suite: e-stop, audible/visual alerts, front/rear proximity sensors and optional blue spot.

Client’s Need

An automotive customer required an in-plant transport solution to move stamping and injection dies from the production area to storage. The system had to be operator-friendly, safe, and efficient in narrow aisles while minimizing handling time and crane usage.

Project Challenge

Die dimensions and weights vary, shifting the center of gravity and increasing risk during tight turns. The route includes intersections and narrow corridors where forklifts struggle to maintain precision and visibility. The solution needed ±90° turning, smooth low-speed control, and reliable stopping on slight ramps.

Our Solution

FADA engineered a 5-ton electric tugger optimized for die handling. The compact frame and steer geometry deliver true ±90° maneuverability for docking to racks and carriers. Proportional traction and braking ensure smooth acceleration and accurate inching. The HMI/handle integrates speed selector, horn, and emergency stop for intuitive single-operator use.

Key Technical Highlights

  • ✔ Capacity: 5 tons; optimized for automotive dies
  • ✔ ±90° turning for tight-aisle maneuvering
  • ✔ Proportional drive & regenerative braking; anti-rollback on ramps
  • ✔ Battery system: LiFePO4 option with opportunity charging
  • ✔ Safety: e-stop, A/V alerts, proximity sensors, optional blue spot
  • ✔ Ergonomic tiller with creep-speed function for precision docking

Result

The electric tugger enabled fast, repeatable die transfers with improved operator safety and visibility. Handling time was reduced, crane usage minimized, and intralogistics flow between production and storage became more reliable—especially in narrow aisles and intersections.





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