Heavy-Duty Material Handling Trolley
A reverse engineering and design optimization project for a heavy-duty trolley used to transport Iron Ore Bins within an industrial facility. The fabricated assembly consists of 27 structural components manufactured primarily from IS 2062 E250BR steel, with a total assembly weight of approximately 4655 kg and a 2-ton load carrying capacity. The project involved dimensional verification, 3D CAD modeling, structural optimization, material assignment, and preparation of detailed fabrication drawings with a complete Bill of Materials (BOM).
The existing trolley required an updated engineering package to improve manufacturing efficiency and operational performance while maintaining its intended load carrying capacity. The objective was not only to recreate the assembly but also to optimize the structure by reducing unnecessary weight, improving handling characteristics, enhancing compatibility with existing plant operations, and developing complete fabrication documentation for future manufacturing and maintenance.
The trolley assembly was reverse engineered through dimensional verification and recreated as an accurate 3D CAD model. The fabricated structure was optimized by refining member layouts and component geometry while preserving structural integrity and the 2-ton load capacity. Manufacturing documentation was prepared with fabrication drawings, weld details, material specifications using IS 2062 E250BR, sectional views, technical notes, and a complete Bill of Materials to support production and inspection.
Successfully developed an optimized digital engineering package for the 27-component Iron Ore Bin Handling Trolley, including an accurate 3D CAD model, fabrication drawings, material specifications, and BOM. The optimized design reduced overall structural weight while improving handling, compatibility, and manufacturability without compromising the 2-ton load carrying capacity. The resulting engineering documentation provides a reliable reference for fabrication, inspection, assembly, and future product improvements.
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