Arduino Based Solar Power Mini Forklift

Abstract

Forklifts are used in a wide variety of applications, such as manufacturing, construction, retail, meat and poultry processing, lumber and building supplies, trades, agriculture, and a variety of warehouse operations. This project presents the design and development of solar powered mini forklift utilizing Arduino as control system. The primary objective is to create an eco-friendly, cost effective, and efficient material handling solution for small-scale industries. In this system, five DC motors, Arduino UNO, Bluetooth module are used. Four DC motors are used for moving and one DC motor is used for lifting. Arduino UNO is mainly used to control the overall system. Arduino UNO will determine whether the motors have to rotate forward or backward. Motor directions are implemented by Arduino programming management. Bluetooth module facilitates communication between mini forklift and a smartphone app which allows the users to execute commands such as forward/reverse, left/right and lift movements. The mini forklift is equipped with solar panels to harness renewable energy, reducing dependence on fossil fuels and minimizing carbon emissions to keep the environment pollution free. Therefore, the system will be a foundation in implementing of the industrial forklift.

Introduction

The project focuses on designing an Arduino-based solar-powered mini forklift aimed at improving industrial material handling by combining automation, energy efficiency, and sustainability. Traditional forklifts rely on fossil fuels or grid electricity, which increases costs and environmental impact. This project integrates an Arduino Uno microcontroller to control the forklift’s movement and lifting functions, while solar panels provide renewable energy, enabling off-grid operation and reducing carbon footprint.

The forklift uses DC motors for driving and lifting, with all components managed by the Arduino. The chassis and mechanical parts are designed using SolidWorks and constructed from mild steel (EN 1.0301) for durability and ease of fabrication. Four geared DC motors drive the wheels, and a wiper motor powers the lifting mechanism due to its high torque.

Experimental analysis shows the forklift safely handles a 10 kg load with stress levels well below the material’s yield strength, ensuring a robust and safe design. The project aims to offer a cost-effective, eco-friendly, and automated solution for small-scale warehouses and educational uses, contributing to sustainable industrial operations through the combination of automation and solar energy.

Conclusion

1) The project successfully demonstrates the integration of solar energy and microcontroller-based control in a functional mini forklift. 2) Utilizing solar power reduces dependence on conventional electricity and promotes environmentally friendly operation. 3) The Arduino platform provides reliable and flexible control over the forklift’s movement and lifting mechanisms. 4) The mini forklift is capable of safely handling small loads, making it suitable for light-duty applications and educational purposes. 5) The design offers a foundation for further enhancements, such as increased load capacity and advanced automation features. 6) This project highlights the potential of combining renewable energy with embedded systems to create sustainable solutions for material handling. 7) The experience gained from this project can be applied to larger-scale implementations and inspire further innovation in green logistics and automation.

References

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Copyright

Copyright © 2025 Shaurya Veer Sharma, Nikhil Gupta, Anuj Ram Tripathi, Pawan Yadav, Rahul Srivastav. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.