Usha B. Trivedi, a qualified mechanical engineer and a technical writer at Hi-Tech Engineering Services, explains how crucial is CAD in the evolution of material handling equipment.

Unlike most equipment, design for fabrication of material handling equipment such as trolleys and pallet forklifts includes generous consideration of ergonomics alongside design detailing precision, cost factor and operation conditions. Ergonomics acquire a prominent position because efficiency of supply chain and accuracy in material transit are directly impacted by it.

With ergonomics taking centre stage for efficient designs, part fabrication and assembly preparation, it becomes essential that fabricators and fitters on the shop floor interpret the information from shop floor drawings correctly. Simultaneously, for the materials handling equipment design engineer, it is necessary to draw the sketches and models correctly in a CAD environment, to ensure every detail is warehoused in CAD models that they set out for fabrication.

Ergonomic design evolution from fixed to modular as CAD engineers see

With CAD in picture, materials handling equipment has evolved from manual to automated systems. But there is equipment like trolleys used in processing plants, which are still handled and operated manually.

However, from a design engineer’s perspective, these components have undergone changes, small or large, with the addition of small features and changes in fabrication process.

The evolution can be easily explained by taking a trolley as an example. Trolleys come in a variety of guises, with positive foot brakes on prestart plastic platforms, hand operated brakes to work on slopes, and foot operated positive brakes to park the trolley with Clax folding and more. For a layman, it might seem all the same, except for some convenience in handling and ergonomics aspects. However, there are technical differences in designing, fabricating and assembling each of these variants that a CAD design engineer knows and understands.

Besides, with gradual advancements in technology, and encouragement of ‘site assembly’ concept, modular trolleys have gained traction all across the industry. A modular trolley can be called to be a structure [temporary or permanent] that can be adapted, reconfigured, and rebuilt as and when the need arises. A CAD design engineer and the material equipment fabricator is well aware of how each part used will assemble with others in order to make the structure stand as one complete structure.

Rationale for modular concept – design standards and customisation

As the difference between concept and idea became clearer and CAD technology was introduced with a concept based design sketching, and standardisation in designs became popular, it facilitated more vivid design alternatives. Feature of modelling each part, for instance screws, brackets, wheels, handles, etc. through different CAD platform offers easy designing. Besides, standard fabrication approach [as per ASME or BS standards] removed the limitation of ‘interchangeability’ for identical parts having multiple applications.

Modelling of each part as per the standard will also result in standard fabrication eliminating any possibility of non-interference or non-mating condition when assembled. Standard part libraries in CAD allowed, and essentially supported, the modular approach that eliminated slightest chances of design inaccuracies and hence fabrication glitches.

Furthermore, the end users too are persistent to have specific design requirements for their convenience. CAD reduces a considerable time for developing customised designs for fabrication and enables faster time to market the product. Better visualisation, sketching techniques, text and PMI – Product Manufacturing Information – annotation in CAD further adds to the ease of designing and fabricating modular materials handling equipment.

CAD modelling will boost the growth of modular equipment fabrication

With a considerable emphasis on ergonomics, discussion about CAD models turn from technicalities to artistic perspective very often. No matter how absurd it seems, but that is the way to design ergonomically sound equipment since ergonomics will directly impact the efficiency.

Standardisation enables design reuse. Multiple standard components can be utilised for different equipment configurations. Parametric 3D models further allow design engineers to make changes in the dimensions and features quickly, speeding up the project delivery.

In fact, a modular approach is already appreciated in industries like wind turbine manufacturing, construction and others. Results of numerous projects show that a modular approach proves to be a catalyst and expedites project delivery significantly. It is about time for materials handling equipment fabricators to know why and how can they leverage the maximum from modular approach in fabrication, especially when CAD is there to favour them all the way from concept to fabrication.

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