Performance analysis of a tri-adjustable automated heavy-duty handling system designed on industry 4.0 principles

Over the years, many South African industries have been using Forklift trucks to move bigger loads from one point to another till today. The use of large forklift trucks within indoor manufacturing processes poses OHS risks to workers as its Internal Combustion Engine (ICE) produces fumes (Carbon Monoxide, CO) when in operation and exhaust fumes, (CO), are harmful to human’s health. On this basis, a new system design is recommended to eliminate the use of MHS that relies on ICE power source to prevent OHS risks in indoor manufacturing industries. In this project, Autodesk Inventor Professional software was used for design development of technical drawings and simulation as well as validation of the new system’s structure. Vehicle Dynamics’ principles and equations are used to determine the overall Rolling Resistance, Tractive Effort of the new system, wheel torque, and the power required to drive the system under 20-ton load capacity. The new system design has been developed to operate using a Hydraulic Power pack source, where it consists of four hydraulic wheel hubs for driving the system, four hydraulic cylinders for lifting & lowering, and a double rod end hydraulic cylinder for steering. Electro-Hydraulic circuit systems were developed and proposed using electronics and fluid mechanics phenomena. Again, principles, laws and equations of Strength of Materials has been carried out for validation of the material selection of the new design system’s structure as well as verifying buckling, deflection & bending stresses, and moments.