Where do innovations happen within the KION Group? For example, in Wangen! Between cowbells and the Lake Constance breeze stands a digital nerve center of the KION Group: In the tranquil town of Wangen, Germany, a team of experts is developing the technologies that bring forklift trucks into the Cloud – and from there back into everyday intralogistics.
2025-06-25
We live in a world where machines whisper to each other. Not with words – but with invisible signals. A forklift truck tells its charger how tired it is. A battery requests energy forecasts. A fleet organizes itself like a swarm, coordinated by algorithms that oversee it like a shepherd watching over the flock.
It's as if things have developed a sixth sense. Not magic, but data. This principle is called the Internet of Things (IoT): an infrastructure where physical objects are connected through data streams and can act smarter, more efficiently and more proactively. And right in the heart of Allgäu, people are hard at work on this.
A typical workplace in Wangen
At the KION site in Wangen, we bring together expert knowledge on the Internet of Things and cybersecurity. “Wangen is not a manufacturing location, it is a center of excellence for developing and delivering innovative IoT solutions in intralogistics,” explains Johann Fischer, Vice President Solutions & Systems Engineering in the KION Group.
With around 25 employees, the KION IoT Systems team focuses on developing and operating the technology infrastructure that enables networking of forklift trucks, chargers and automated vehicles with cloud solutions. “We are a key hub in our digitally connected intralogistics strategy,” Fischer emphasizes: “From here, we lay the groundwork for seamless data connectivity and support new standards for smart truck fleets.” The innovation site operates as an independent limited liability company within the KION Group but collaborates closely with our forklift brands.
Unlike traditional production sites, the focus in Wangen is entirely on software, connectivity solution development and security. Cybersecurity is especially important: Wangen advises the Group’s brands internally on cyber risks and develops solutions that comply with the requirements of the upcoming EU Cyber Resilience Act. This way, Wangen plays a significant role in supporting the digital transformation of the entire KION Group.
Hand recognition with keypoint detection
The KION Connect Unit (KCU) is an IoT gateway installed directly on the forklift. It collects machine data and connects the truck to the Cloud via mobile networks. This Linux-based device enables real-time transfer of truck data to the Cloud. This allows fleets to be monitored and configured at any time.
Through the KCU, driver profiles can be customized – for example setting the maximum speed for a specific driver or restricting truck use to valid certifications only. Typical features include managing driver authorizations and automatically verifying digitally stored driver's license data.
In response to EU regulations – such as the upcoming Cyber Resilience Act (CRA) – KION IoT Systems develops specially secured software and standards. The team also provides in-house IT security consulting and ensures all IoT components comply with CRA requirements. This results in robust system designs that meet global security standards and enhance the resilience of the truck fleet.
The technical foundation for the “Internet of Things” consists of modular building blocks. At the heart is the aforementioned KCU, which manages all tasks on the truck. Every new connected KION truck contains a so-called KCU box – the central control unit for data transmission. It transmits information via mobile networks directly to the Microsoft Azure Cloud, a central, Internet-based storage and computing platform that can be securely accessed from anywhere. There, truck data is collected, analyzed and made available for various applications such as maintenance, fleet management and software updates. The development and implementation of these applications is carried out in collaboration with other KION teams.
KION currently operates more than 800 IT systems in the Cloud. This approach ensures scalability and high availability. At the same time, developers follow an API-first philosophy, meaning: Interfaces (APIs, short for Application Programming Interfaces) are considered from the start, are developed in a standardized way, and are consistently available across all product lines. This ensures that all industrial trucks across our brands can be seamlessly integrated into comprehensive fleet and software systems.
When customers use their trucks more efficiently, they immediately save costs.
Digitalization of modern industrial trucks begins within the truck itself: Sensors continuously capture operating data, which is transmitted to the Cloud via the KCU box. Precise digital replicas of the trucks are created in the Cloud – synchronized with their actual condition. This allows a service technician to instantly see, for example, if the motor is reporting an anomaly or if maintenance is due.
Numerous smart services can be built on this digital foundation. Using the modern Over-the-Air (OTA) update process, software patches and feature upgrades can be directly installed on the trucks, for example during the night or scheduled downtimes.
One specific application is the "Truck-to-Cloud" service developed in Wangen: Truck data is continuously transferred to the KION Cloud. This real-time connectivity provides transparency over fleet utilization, simplifies energy management, and supports data-driven operational decisions. "When customers use their trucks more efficiently, they immediately save costs," explains Lorenz Schmid, Product Director IoT Systems.
Additional networked services are also being developed on the IoT platform: Condition-based updates, dynamic energy optimization depending on battery status, or multi-site fleet control are just a few examples.
• Predictive maintenance: Sensors detect wear or malfunctions well before any failure occurs. This allows repairs to be scheduled before downtime happens.
• Fleet optimization: Cloud-based connectivity leads to higher utilization rates. The increased transparency enabled by “Truck-to-Cloud” alone significantly reduces idle time and therefore cuts costs.
• Flexibility for customers: Software updates and new features are delivered "Over-the-Air" – much like with smartphones. As a result, customers automatically receive new functionalities.
The Wangen site exemplifies our forward-looking KION digital strategy. For Johann Fischer, it is clear: "With the platform developed in Wangen, we create the enablers to quickly scale innovative functions for the KION fleet and consistently stay one step ahead of the competition."
