Transportation within plants and industrial areas in the energy industry has long presented challenges, requiring engineers to prioritize safety and efficiency. Morello’s customized self-propelled trolleys offer a solution to these challenges. Tailored to meet specific needs within the energy sector and individual work environments, our heavy-duty carts have been pioneers in material handling customization since our company’s inception.
Handling equipment weighing several tons, such as large transformers, heavy coolers, turbines, and generators, poses significant logistical challenges in the Power Generation sector. In addition to transportation during production and logistics phases, positioning heavy and non-standard items and components upon reaching their final destination is a critical task.
We present two cases from our project portfolio that vividly demonstrate the efficiency, safety, and customization opportunities provided by our heavy-duty carts designed for the energy industry. In addressing the challenges of this sector, we have truly revolutionized production dynamics for these two companies.
Case 1: Streamlined handling of power transformers in the USA
A leading international supplier of large power transformers in the United States faced a challenge in handling overloaded transformers weighing up to 33 tons, including their hefty windings, during the manufacturing process. At that time, the company was using trolleys with air cushion technology, which encountered issues due to the lack of a perfectly flat and uniform floor. Moreover, these trolleys had high energy and compressed air requirements, limiting their usability within the factory. Additionally, the restricted maneuvering space for transformers that also needed to be raised posed further challenges. Another concern was the limitation in power supply, hindering the freedom of movement of the self-propelled trolleys both inside and outside the shed.
Our solution involved designing two omnidirectional self-propelled trolleys with precise technical specifications developed in collaboration with the senior engineer in Production Control. Omnidirectional steering, where each wheel could move independently, effectively addressed the maneuvering issues in confined spaces. We equipped the trolleys with polyurethane wheels and rubber tires as alternatives suitable for all system surfaces. These multidirectional self-propelled trolleys featured efficient lifting mechanisms positioned under a steel structure, using a hydraulic system for easy lifting and repositioning as needed. These fully electric battery-powered trolleys were equipped with modern electric motors for both traction and steering, ensuring greater autonomy, maneuverability, and cost-effectiveness.
The integration of our customized equipment provided a safe solution for handling power transformers within the factory, enhancing operational flexibility while ensuring safety and risk-free operations.
Case 2: Versatile handling of heavy coolers in India
A prominent manufacturer specializing in heating, cooling, water, and waste management, and building a new plant in India, approached us for an effective solution in handling large coolers weighing up to 65 tons. The plant’s design incorporated the use of transfer trolleys on tracks for handling heavy materials, necessitating the installation of a fixed track system and the use of 2 coordinated self-propelled trolleys. However, we offered a more efficient and cost-effective solution.
Semi-finished coolers, each weighing up to 65 tons, needed to be transported to various work areas throughout the plant, both indoors and outdoors, at different stages of the production process. Limited space and load distribution were significant challenges, particularly as larger coolers concentrated their weight on their ends.
Collaboration with the Process Engineer led to an alternative solution that addressed these operational challenges. We proposed 12-meter multidirectional self-propelled trolleys as the ultimate and perfect alternative to rail-based handling. Omnidirectional steering resolved all directional and space-related issues, while a single self-propelled trolley provided higher speed of movement, eliminating the limitations of rail transportation. An optimized plant layout removed rail-related constraints and the need for a pit required by the second transfer trolley. The single cart proved to be a more cost-effective solution in terms of both purchase and maintenance costs.
The design of these heavy-load self-propelled trolleys took into account the uneven weight distribution inside the cooler, ensuring optimal load transportation. Careful calculations using Morello’s proprietary software ensured safe movement and operation. The loading surface of the trolley was raised and adjusted with a hydraulic system to maintain a horizontal position at all times, compensating for any slopes during handling operations. Equipped with 4 safety laser scanners positioned on each side, these trolleys ensured safe handling of heavy loads both indoors and outdoors. The use of brushless electric motors demonstrated high precision and cost-effective maintenance.
Furthermore, the installation of a remote assistance card on all self-propelled trolleys enabled rapid diagnosis and technical support directly from our headquarters. In the event of required technical assistance, Morello’s network of international technical partners ensures prompt and professional maintenance.
Our portfolio of customized, high-quality material handling solutions for the energy industry perfectly illustrates our ability to develop solutions of any scale and complexity. Contact our team to receive detailed information about our services and equipment.