Category: Blog

Huge wind turbines with extremely long blades extract all the energy from the wind, but have you ever imagined how they are built? Manufacturing process with such heavy-load and huge components requires nonstandard solutions to be moved safely and securely both inside and outside the production site.

Customization is the key feature in material handling for wind energy sector where Morello provides solutions with its customizable industrial transport trolleys. Our solutions are based on some fundamental aspects of material handling including physical place available for transportation, total safety, traction technology, technical support and environmental issues.

India and France are among the top 7 countries in the world for installed wind power capacity and Morello is proud to have supplied heavy duty industrial trolleys for handling wind turbine components for projects in these two important markets. Wind power capacity has increased significantly over the past decade and new wind farms are continuously developing.

We provide 2 cases for manufacturers of blades and gearboxes for wind turbines that effectively illustrate Morello solutions in wind energy sector.

1. Handling longest wind turbine in the world

Famous global manufacturer of large wind turbine blades based in France challenged us with handling of longest wind turbine in the world! 108 meter-long blade weighing 80 tons was perfectly handled by a combination of customized self-propelled trolleys designed by Morello.

Moving so large and overload structure clearly required two synchronized heavy duty industrial trolleys to support each end of the blade considering length and weight of the blade. The biggest challenge was flexible and non-rigid structure of the blade. This was the first case in history when wind turbine blade was transported with two synchronized modular transfer carriages without using a rigid structure to support the blade. Our customized self-propelled trolleys had to move both inside and outside the plant and the customer required a lifting mechanism on the trolleys. To load paddles onto a ship, our trolleys also required enough power to travel to the port and along the dock.

Morello project involved built two fully customized and synchronized SPMTs (Self-Propelled Modular Trolleys). First goal was communication between trolleys using own Wi-Fi network to synchronize the speed, acceleration, braking and steering positions of each individual wheel. Our brand-new software program perfectly managed synchronization of movement as there was no rigid structure between the two trolleys with operation distance of 80 meters. Hydraulic suspensions for each shaft line and modern electric motors were installed with battery-powered drive and steering for completely green and ecological solution featuring also lower energy consumption and extremely low maintenance costs without giving up performance and productivity.

2. Handling wind turbine gearboxes in India

Leading manufacturer pioneering production of wind turbine gearboxes and transmissions asked Morello for solution to move extremely heavy products. We provided relatively small, customized industrial transport trolley to handle gearboxes of 100 tons. Gearbox had to be placed on a steel structure of trolley not larger than 4 x 2.7 meters and (pallet). No bridge crane or suspended load for greater safety and design for both indoor and outdoor handling. Moving a 108-ton gearbox with a trolley of this size required careful machine design featuring also operator recognition and registration upon client’s request.

Collaborating with Wind Power Technology Business Unit we designed super compact, omnidirectional, self-loading industrial truck for heavy loads, designed to carry a total load of 108 tons. Radio-controlled trolley features omnidirectional steering with independent steering and electric motor on each wheel. Our customized solution was provided with hydraulic suspensions to work on imperfect flooring and a lifting loading surface. High-precision brushless electric motors do not require maintenance while advanced diagnostic system and IoT technology ensure remote assistance.

Wind energy sector remains one of the most exciting for manufacturers of material handling equipment. The impact of Morello customization expertise is particularly visible in this sector while clear energy trends open big future for our ideas and projects.

Recently Morello delivered a heavy duty platform cart designed specially for an automotive customer.  This cart can move dies up to 40 tons within the production facility, and, thanks to its electric motor and battery power, it is possible to easily move very heavy dies around the warehouse, from one bay to another and even from one warehouse to another, traveling even in both open and asphalted areas. Specifically on account of the need to travel on asphalt roads with a load as low to the ground as possible, this heavy duty platform cart is designed with 16 wheels and 4 axle lines, in order to best distribute the load over each axle and over each wheel.

The cart is designed to transport dies of various weights and dimensions, and is actually equipped with a load-bearing frame that permits loads that are highly concentrated and of decidedly reduced dimensions. At the center of the loading bed has also been added a layer of polyethylene to avoid damage to the surface of the die transported. The wheels of this heavy duty platform cart are anti-marking and guarantee leaving no unsightly marks on floors that must always remain clean. All of the axle lines steer up to 45°, both front and rear, and are all connected by an elaborate lever mechanism. And because of this type of steering the steering radius of this heavy duty platform cart is extremely small, making it extremely maneuverable and ideal for moving dies even in relatively tight spaces.

The safety features of this cart are manifold. The cart is equipped with 4 emergency buttons, 2 laser scanners and anti-crush guards on all external wheels. A notebook is also furnished, which is suitable for quick and efficient remote maintenance, if needed. On request this heavy duty platform cart can also be provided in an AGV version, with completely automatic guidance, acting to thereby optimize the customer’s handling processes. Morello makes battery powered transporters with different designs and each electric cart can be customized on the customer’s request in each and every detail. Check out some examples here: Battery powered transports

 

SGAI VCP3
40 t – 4,800 x 2,200 mm

Main features:
Capacity: 40 t (up to over 500 tons)
Steering: all axle steering
Power: lead-acid battery (gel, lithium and others on request)
Traction motors: AC
Steering motors: AC
Size: 4,800 x 2,200 mm (other dimensions on request)
Speed: 20 m/min
Battery range: 5 km
Control: radio control + pendant push button station
AGV: on request
On request: Ex conformance (Class 1 and 2, Division 1 and 2, Zone 1 and 2, dust and gas)

For a major EPC company operating in the oil and gas sector, Morello has designed and produced a series of electric omnidirectional explosion proof trolleys.
These battery powered explosion proof trolleys have been designed taking into account very special requirements of the customer, who needed to move extremely heavy materials on special ships used for collecting and storing oil and natural gas, called FPSO and FLNG.

In order to be able to operate under such a demanding environment, the explosion proof trolleys had to conform to extremely rigid technical specifications.
First of all the machine had to be suitable for working in an offshore environment, which can be extremely corrosive for all of the onboard components. There is also the risk of water spouts, some very violent. For this reason stainless steel components are used with a minimum IP65 protection.

Another very complex challenge that has to be faced is the fact that these explosion proof trolleys have to operate on a ship. A ship presents three main problems for trolleys carrying heavy loads: it is in constant motion, has pitch and also roll. In the first place it is therefore necessary to calculate how the forces deriving from this movement influence the structure of the trolley and of the ship’s floor, which is not suited to support extremely high peak loads. Moreover it is necessary to calculate the power requirements needed to operate these explosion proof trolleys, taking into account the the fact that the pitch and roll involve even higher gradients that need to be overcome (over 16%!). Finally, it was necessary to carefully consider safety factors, guaranteeing a coefficient of friction suitable for avoiding slippage in cases of sudden movements of the ship and overturning of the trolley from a shift in the center of gravity of the transported load.

In addition to the above mentioned issued, perhaps the most critical is the environment at risk of explosion typical of ships used for the extraction and storage of fossil fuels. For this reason these explosion proof
trolleys are fitted exclusively with ATEX components and are ATEX certified by a certifying body that has inspected the design and production.
One very special feature of these explosion proof trolleys is that they have been provided with a battery charging station that is also ATEX certified. Consequently, it is possible to recharge the trolleys’ batteries even in ATEX classified, danger zones.
Given the restricted spaces of a ship these explosion proof trolleys are completely omnidirectional, and can therefore move in any direction, optimizing the maneuvering space.

Morello produces ATEX and IECEx trolleys for explosive environments with different designs and each electric trolley can be customized on the customer’s request in each detail. Check out some examples here: Exposion proof trolleys

OMNI DR
12 t – 3,800 x 2,500 mm

Main features:
Capacity: 12 t (up to over 500 tons)
Steering: omnidirectional
Power: ATEX certified gel battery (lithium, lead-acid and others on request)
Traction motors: ATEX certified brushless AC
Steering motors: ATEX certified brushless AC
Size: 3,800 x 2,500 mm
Speed: 30 m/min
Battery range: 5 km
Control: pendant push button station

Morello has recently manufactured a full electric truck for the transport of large loads inside industrial plants

In fact, ever more frequently, companies the world over are having to deal with the problem of pollution caused by diesel vehicles. The movement of diesel vehicles inside plants is starting to be often prohibited, even out-of-doors. For this reason, many of our customers are converting their transport vehicles, even those of the largest capacity, from ones powered by combustion engines to those with electric motors run on battery.
In particular, in many they are replacing the diesel trucks they use to move materials from one warehouse to another with battery powered electric trucks. These electric trucks are also very useful insofar as, in addition to making outdoor transport more eco-friendly, they also have the possibility of working inside warehouses, indoors, something that diesel trucks cannot do.

Our full electric truck also has some extremely beneficial features making it the perfect eco-friendly replacement for diesel trucks. This vehicle is powered by a high energy density lithium battery, which allows for extremely fast recharging times. Hence, autonomy is not a problem, even for companies that work 3 shifts.

This full electric truck, thanks to its electric motor, controlled by PLC and the latest generation of inverter, enjoys an extremely high level of efficiency. This efficiency, along with the minor cost of electrical energy when compared to the costs of diesel, guarantees an annual savings in the thousands of dollars, making this full electric truck more economical in the midterm than a truck with a combustion engine.

Another very important feature of this full electric truck is its versatility. Morello is in fact able to customize this vehicle in any way. We can make electric trucks with capacities of 2 tons up to over 100 tons. We can customize the dimensions and shape of the loading bed based on customer requirements and the load that needs to be moved (in this particular case, the customer had to transport steel coils for which we designed a special V-shaped saddle for holding the coil). We can also define, together with the customer, battery life and truck speed. On request, we can even customize the vehicle to travel on public thoroughfares. Contact us for a free consultation about your needs. Morello exports its battery powered electric trucks the world over.

SGAI VSF – CABIN
40 t – 7,600 x 2,500 mm

Main features:
Capacity: 40 t (up to over 100 tons on request)
Steering: front steering axle
Power: lithium battery
Traction motors: AC
Steering motors: AC
Size: 7,600 x 2,500 mm (other dimensions on request)
Speed: 6 km/h with full load (up to 30 km/h on request)
Battery life: 10 km
Control: driver’s cab
Adapted for public streets: on request
AGV: on request
On request: Ex conformance (Class 1 and 2, Division 1 and 2, Zone 1 and 2, dust and gas)

Based in Turin since 1946 Morello company enhanced international market of tailor-made solutions for on-site material handling and logistics in the variety of industrial sectors. While in 2020 international markets are essential, we focus on global presence creating new partnerships with top tier multinational corporations. The main drive of our international success is based on series of factors blending support service excellence and attention to detail in key heavy industry sectors.

Solving client’s problem

Our key expertise is represented with customized solutions for heavy-load material handling and logistics involving cargo up to and over 1000 tones. Accepting particular heavy load challenge of every client we involve them the whole way through the process to achieve precise result. Morello has a clear and focused approach to problem solving and this pathway is followed with each customer and for each project. As each new project is custom built the initial focus is always on assessing the client’s needs, collecting and analyzing client data and together with the client company evaluating the most suitable solution and technology.

Know-how in every sector of heavy industry

Each sector has its specific requirements and issues while Morello applies a detailed analytical approach to assess the company’s concrete material handling needs within specific industrial environment.

Solid experience in on both local and international markets ensures widest expertise even for most specific heavy industry sectors. From shipyards to defense industry, from construction to metalworking, Morello customized products provide efficient solutions for transportation and handling of heavy loads.

Manufacturing industry all over the world use Morello equipment to move large equipment and presses on automotive, power generation and steel plants and industrial areas. In the energy sector, Morello has produced self-propelled trucks for the oil and gas sector, nuclear and wind installations. ATEX certified transport systems and self-propelled trolleys is a great advantage in these sectors. The process industries, such as chemical sector also apply Morello self-propelled motorized trucks for onsite material handling.

Smart Advanced Technologies

Morello works with the most advanced, refined and smart technology to introduce new levels of performance and safety. Our customized material handling solutions feature advanced IoT, Industry 4.0 and smart technologies. Power supply feature complete range of options from lithium batteries to diesel engines focusing on electric motorization, brushless motors, more durable and precise than standard AC variants providing the core of our self-propelled carts. Advancing safety we use complete range of sensors including navigation, positioning, diagnostics and more functions. Steering options include omnidirectional and multi-directional steering for enhanced maneuverability.

IoT solutions provide Remote Assistance on all our self-propelled trolleys. We use our own software for easy and immediate integration with the customer’s automation. More customization options include human-machine interface and control functions, smart vision, imaging technologies and latest AGV technologies.

Sophisticated Project Management

Dealing with complex project helped Morello to develop unique expertise in Sophisticated Project Management. Efficient and reliable project management system is essential when each project is actually custom-build. After project team is set up a series of documents and procedures ensure high level of project quality and control: we manage Project Quality Control Plan, Vendor Data Requirement List Agreement, Master Project Schedule + Critical Path, Welding Book, Project Risk Analysis, FAT & SAT Procedures and more documents while Client Progress Report keeps the client informed of the project’s progress all the way through. Working with Global Corporations means that Morello can respond to the most severe quality standards and data requirements applied in largest multinational companies across the world.

The result is what defines working with Morello

These drivers helped Morello to build a strong international reputation and presence to become supplier of the largest industrial corporations around the world.

Contact us for proper introductions of our unique expertise and customization opportunities. We will happily guide you through the Morello Pathway, our communication with clients, Morello Smart Technologies, Sophisticated Project Management and refined solutions for each specific industry.

Demanding steel industry is one of key Morello expertise with solid experience in industrial material handling. Extreme environment of steel industry plants is perfectly suiting material handling equipment from Morello such as heavy duty self-propelled trucks and coil transport trolleys supplied to steel industry companies in the United States, Mexico, Germany, France, United Kingdom, Spain, Russia, Poland, Eastern Europe, Middle East countries and all over the world.

Metalworking industry unlike many others develops extreme conditions and temperatures, fumes and vapors, dust and fibers in the atmosphere and causes the flow of hot liquid metals creating a complete range of material handling risk factors that must be managed and contained.

Proper planning of heavy-load material handling is cost-effective, generate a safer work environment, contribute to corporate sustainability goals, reduce inventory, improve operational efficiency and ensure lead times and faster delivery. Let’s take a look at two specific applications where Morello has helped steelmakers improve their operational performance.

STEEL PIPE PLANT PROJECT

Located in Texas, USA steel pipe plant challenged us with a system to move the rolling stands used for seamless pipe production. The plant must continuously change the rolling stands to produce steel pipes of different diameters.

Challenge: There was a complex of tasks to implement. Starting for the loads weighed up to 65 tons with up to 6 rolling stands available for simultaneous movement. The equipment had to be moved in two directions, both parallel and perpendicular to the rolling mill. A heavy-duty self-propelled trolley system was required to move one or more rolling stands to the required locations. The plant environment also presented some operational issues.

Solution: 8 industrial self-propelled rail trucks were used for material handling. 6 rail trolleys handling up to 65 tons were used to bring the stands in front of the rolling mill moving parallel to the rolling mill. We can call these rail trucks the cage transporters using RFID to recognize specific cages. 2 rail trolleys handling up to 100 tons were used to transport the cage conveyors (including cages) from the rolling mill area to the storage area and vice versa. They then move perpendicular to the rolling mill, underneath the “cage conveyors”.

Morello designed and developed the whole system. This included all operations and handling of industrial self-propelled trucks in response to production requirements, precise positioning of the trucks, automatic battery recharging, safety aspects, Wi-Fi communications with the plant’s IT systems, exchange data and diagnostics connected to the central system.

The video below demonstrated the system in action:

https://www.youtube.com/watch?v=IdwZzJob_hs

PROJECT FOR A PLANT MANUFACTURING STEEL COIL

Steel coil production plant in Mexico required effective solution for movement of steel coils within the plant. This operation included loading, transfer and unloading – a standard process for steel mills of this type using “coil car” and machinery such as coil transport trolleys.

Challenge: software integrated into the plant’s operating system ensured automated operation of coil car. The shuttles for the coils receive the steel coils that rest on saddles and, in this case, they must be able to transport coils up to 35 tons. The coil carriage can lift the load 1100mm (4.3ft). The unloading process can be managed in two ways. Or, simply by lowering the saddles of the coil car onto another support structure or, alternatively, by equipping the coil carriage with motorized rollers which, if inclined, roll the coil onto another support structure.

Solution: For this specific plant in Mexico, Morello supplied a total of 3 coil cars.

The video below demonstrated load tests:

https://www.youtube.com/watch?v=sbFG_22KWPY

For more information on our material handling solutions click our product page.

Morello Customer Loyalty Team: Amedeo Morello, Luca Tibaldi, Stefano Rizzo

We are looking forward to discuss your project.

Morello has designed and produced an omnidirectional mover cart with 30 ton capacity for a large German company.

This type of omnidirectional mover cart is the most flexible cart in all the Morello line and is perfect for optimizing the transport of heavy loads in industry under diverse profiles: timing, spatial, safety, energy consumption and environmental.

One of the most important features of this cart is its steering type: it is able to move in any direction, thanks to its completely independent wheels. This is truly an omnidirectional cart. This feature guarantees the ability of moving about even in the most restricted spaces, allowing a plant layout that doesn’t require large spaces for the transport of materials.

This omnidirectional mover cart is also equipped with a loading bed that can be raised by about 200 mm. In this way, it can lift a load, transport it and deposit it without the aid of gantries or other lifting equipment. This feature allows it to optimize maximally transport times – with a single machine it is possible to transport loads of any type from one bay to another or even from one warehouse to another; without considering the extreme ease with which it is possible to rotate large cumbersome loads 90°, 180° or 360°, all in the fastest times.

The movement along the ground permitted by this omnidirectional mover cart also notably increases safety. No longer are there loads suspended around the plant. The load is always at human height, readily visible and always signaled by the warning sound and flashing lights mounted onboard the omnidirectional mover cart. In order to increase safety it is also possible to equip it with laser scanners that stop the cart when obstacles fall in its path. 4 emergency push-buttons at the four corners finally complete the available safety features.

Energy consumption and the environmental aspect are other strong points of this omnidirectional mover cart designed and constructed by Morello. The cart is powered by a lithium battery and can therefore work in any environment, both indoor and outdoor, as it is completely non-polluting, both during use and during charging. Energy regenerating brushless traction motors and the high energy density battery guarantee maximum efficiency, permitting a large savings in electrical consumption.

To complete all of these features, this omnidirectional mover cart can also be provided as an AGV, with completely automatic guidance, therefore working to optimize the customer’s material transport processes.

Morello produces this type of omnidirectional mover cart for the United States, Europe, Central and South America, Asia and Australia, and in general for the entire world.

Morello produces battery powered transporters also with different designs and each electric cart can be customized on the customer’s request in each and every detail. You can see some examples here: battery powered transporters

OMNI-E DP
30 t – 5,500 x 2,600 mm

Main features:

Capacity: 30 t (up to over 1,000 tons)
Steering: omnidirectional
Power: lithium battery (gel, lead-acid and others on request)
Traction motors: brushless AC
Steering motors: brushless AC
Size: 5,500 x 2,600 mm (other dimensions on request)
Speed: 30 m/min
Battery range: 7 km
Control: radio control
AGV: on request
On request: Ex conformance (Class 1 and 2, Division 1 and 2, Zone 1 and 2, dust and gas)

MORELLO FOR OIL & GAS OFFSHORE PROJECT: ATEX HEAVY DUTY PLATFORM CARTS

Oil and Gas is one of the most demanding industries including material handling requirements. Heavy duty platform carts used on offshore platforms in particularly severe environments require particular attention in terms of durability and technology. And ATEX carts make a part of Morello expertise.

Offshore platforms blend severe environment, aggressive weather and particular operation conditions: sea air and saline and volatile, hazardous environment create challenging conditions for any equipment including heavy duty industrial carts. This is the story of a demanding project on an offshore oil and gas platform in the Atlantic Ocean near the coast of Africa.

Client and Location:

Total Energies Egina oil field is located about 130 kilometers off the coast of Nigeria at water depths of more than 1,500 meters. It is an ultra-deep flagship offshore project.

Samsung Heavy Industries was Morello’s direct client. Morello heavy duty platform cart operated on an FPSO vessel for floating production, storage and offloading. This vessel extracts and stores millions of barrels of crude oil.

Job Challenge:

Object	28-ton rotor of a large generator requires regular extraction for maintenance operations on an FPSO vessel. The client called our ATEX cart “the rotor extractor”.
Object movement	The rotor had to be extracted to a height of 4m, lowered to 3m to avoid contact with other equipment, and transferred to a different location on the FPSO vessel.

Working Environment:

Working Area	Hazardous offshore area with explosion risk requiring carts with ATEX/IECEx certifications
Space	On an FPSO, a floating vessel, in the middle of the ocean with limited space available and tight maneuvering angles
Weather Considerations	Morello heavy duty industrial cart will spend its entire life outdoors in all seasons and salty weather conditions on the open sea and must be able to manage the roll and pitch of the vessel
Air Quality	Sea air, saline environment with aggressive weather conditions
Flooring Conditions	The surface of the FPSO vessel is not built to withstand extremely heavy loads and so the weight distribution, accounting for roll and pitch, must be stable and dynamically balanced. The flooring will often be wet and so the risk of slippage during roll and pitch movement had to be managed
Location & Service	Being located in the middle of the ocean, Morello ATEX cart must be an exceptionally reliable machine, while breakdowns are not easily repaired.

Morello Solution:

Vehicle	Battery-Powered OMNI heavy duty platform cart featuring electric motors. Only certified IP protected electrical components were used, with stainless steel materials preferred and a certified C5-M marine paint finish applied
Steering	OMNI heavy duty industrial cart featured multi-directional steering able to navigate in tight spaces and drive with front and rear steering, at 90°, diagonally, rotate on its axis and more directions.
ATEX Certified	All electrical and mechanical parts and the engineering design must ensure zero explosion risk and be certified to make ATEX cart of full value. This required a complete revision of the machine’s specifications and components. The battery charger must also be EX certified
Mobility	To manage the ground pressure effect and avoid overloading at any single point, dynamic acceleration calculations were made to ensure an even load bearing in all sea conditions on a floating vessel. This Morello cart has 3 axis lines for a total of 12 individually motorized wheels! To ensure optimal grip and surface adherence all 12 wheels were individually motorized and the hydraulic suspension ensured that all 12 wheels were continuously grounded. Specific calculations were made to measure friction levels between the materials of the vessel floor and the cart’s wheels in wet and dry conditions
Load platform	Equipped with a load platform combined with a scissor lift to bear a 28-ton load raised to a height of over 1 meter. The load platform also has rails on which the rotor is maneuvered into position using a winch. To ensure the platform remains stable during the loading procedure the cart is equipped with 4 hydraulic stabilizers at the 4 corners
Motors	AC brushless electric motors, no maintenance, no pollution
Operating Control	The vehicle is driven using a radio-controlled unit with potentiometer. The operating software is Morello proprietary software used globally, developed and fine-tuned over many years
Technical Support	Zero maintenance components were used wherever possible Potential failure risks were identified and minimized Backup intervention procedures were outlined in case of need Backup spare parts were provided to ensure 100% efficiency Vehicle Diagnostics available on advanced HMI Remote Assistance active with on-board monitoring software
Project Management	Morello project teams have many years of experience supplying technical solutions to challenging industries such as oil and gas, the nuclear sector and chemicals, to name a few, which require a high level of technical project management, technical documentation and support

Contact Morello Expert Team to discuss your project:  Amedeo Morello, Luca Tibaldi, Stefano Rizzo.

INDUSTRIAL MATERIAL HANDLING AND TRANSPORTATION SYSTEM SOLUTIONS FROM MORELLO

Morello is material handling equipment supplier with a growing global business covering 30 international markets. Morello produces customized material handling equipment for industrial transportation of heavy loads over 1000 tons.

As a material handling company Morello pioneered customization of heavy load industrial handling equipment, 100% designed and manufactured in its factory in Turin, Italy.

Industrial material handling and transportation system solutions from Morello include complete catalogue of standard heavy duty trolleys for a complete range of industrial application, yet unique expertise of the company is customization of heavy duty carts and trolleys.

Each industrial company has specific objectives to achieve including both company performance indicators and and project goals. When Morello discusses a project with a client there is a clear focus on concrete problem solving translated in customized equipment solution. This approach defines Morello among material handling equipment manufacturers.

Key performance indicators defined by a client usually cover following aspects:

Morello expertise in customization of industrial material handling is perfectly blended in key aspects of project development:

These essential factors together shape Morello as leading material handling equipment supplier is critical to a successful outcome depending on performance indicators, factory environment, personnel factors, product loads and more conditions.

Contact our Expert Team of Amedeo Morello, Luca Tibaldi, Stefano Rizzo.

DIESEL OR BATTERY POWERED CARTS? DIFFERENCES BETWEEN ELECTRIC AND HYDRAULIC MOTORS FOR HEAVY DUTY TRANSPORTATION

Morello offers unique expertise in manufacturing of custom-made heavy-duty platform cartsfor global industry. Transporting weights of up to 1000 tons, Morello solutions are 100% tailored to the client’s operational requirements.

The key factor impacting the performance of any heavy duty carts is the power supply and type of engine with which the vehicle will be fitted. Morello offers three essential solutions including battery, diesel and hybrid heavy duty carts.

Considering issues related to diesel-powered carts, more and more industrial companies are seeing and understanding the benefits of battery powered technology and electric motors.

Battery powered solutions represent key area of expertise in Morello and as battery technology continue to develop this will allow for even greater benefits going forward. Our battery powered cartsare by far the most popular choice for industrials as the advantages significantly outweigh the benefits of the diesel power alternative.

Let’s have a closer look at the specific advantages.

Advantages of battery powered carts with electric motors

1) Preventing air pollution: electric motors are emission-free, they can be used both indoors and outdoors without danger of impacting air quality.

2) Preventing noise pollution: battery-driven solutions are infinitely quieter than diesel-powered carts powered by a noisy hydraulic pump and so reduce factory noise pollution, especially beneficial in a 24-hour, day and night, working environment.

3) Cost-effective while electricity is cheaper than diesel. Electric motors, driven directly by battery or diesel generator, are more efficient compared to diesel carts.

4) Zero Maintenance for battery powered carts provide cost and efficiency benefits that are self-evident.

5) Remote Monitoring of batteries, especially lithium batteries that can be configured and monitored remotely for working hours, usage, wear and tear reducing downtime. An electric motor, fitted with sensors, can be precisely controlled. The remote monitoring and management possibilities ensure greater precision and maneuverability, better diagnostics, overall reliability, less downtime, and greater automation. This is not possible with hydraulic motors.

6) Innovative solution with the possibility of increased automation, zero environmental impact, and remote monitoring for efficiency. Battery-powered carts are the lowest risk and long term investment.

7) Safety benefits of electric motor guarantees higher level of safety than one with a hydraulic motor. An electric motor has all the in-built safety features and components provided by the major automation component manufacturers including Siemens, SICK and others.

8) Useful life of battery-powered carts equipped with electric motor provides easy and cheap replacement compared to a hydraulic motor.

Advantages of hybrid heavy duty carts

Hybrid models compared to full electric solutions provide a useful alternative option for one specific reason: unlimited operation autonomy. The Hybrid can continue working indefinitely as it does not have to stop to recharge, or to change batteries (remove the rundown battery with a charged battery). The operator can switch from battery power (completely emission-free) to diesel power simply by turning a selector. While hybrid heavy duty carts run with the diesel generator set to power up the on-board battery.

With more on-board technology it is obviously a more costly option which must be evaluated based on a company’s operation goals.

Heavy Duty Platform Cart Models

Today customized battery powered carts represent key Morello expertise. Here are some examples of our solutions.

Battery powered carts with electric motor:

• Battery powered electric truck, with on-board driver cabin, for handling large loads within industrial plants. Load capacity is 40 tones; Platform is 7.6m x 2.5m

• 2 battery powered SPMTs for an important Indian multinational. Load capacity is 25 tones; Platform is 5m x 2.9m

• Precast tunnel lining transporter for the Tideway Tunnel project in UK – Load capacity is 60 tones; Platform is 5.4m x 1.7m.

Diesel powered carts with electric motor:

• Steel Mill yard, outdoor use, heavy duty transporter. Load capacity is 130 tones; Platform is 6m x 3m.

Hybrid heavy-duty carts:

• Diesel-electric hybrid versatile truck for both indoor and outdoor material handling. Load capacity is 20 tones; Platform is 3.3m x 2.4m.