This case study details how REMARKABLE customized a 90 Ton Explosion Proof AGV Transfer Cart for a wind power plant to address the plant’s challenges with handling heavy loads and transporting materials.
Project Background
The customer is a wind power equipment manufacturer specializing in wind turbine towers, nacelle structures, hub supports, and large steel components.
The factory covers approximately 120,000㎡ with 3 production lines and an annual production capacity of 800+ sets of large wind power components. During production, some large components weigh 80–90 tons and need to be transported among the welding, assembly, inspection, and storage areas.
The existing transportation method used 50-ton forklifts and overhead cranes, which could not meet the requirements for handling heavy components. The customer required an automatic transportation solution with higher load capacity, flexible movement, and safety protection for internal factory logistics.
Problems to Be Solved
The customer’s existing handling method had limitations in heavy load transportation, operational efficiency, and safety management. A new transportation solution was required to support large component movement inside the factory.
- Insufficient Load Capacity: Existing equipment could not handle 80–90-ton wind power components.
- Low Transportation Efficiency: Forklifts and cranes required multiple operations and increased transfer time.
- Limited Transportation Flexibility: Traditional handling equipment could not support flexible movement between production areas.
- High Safety Requirements: The customer required automatic transportation with safety protection functions.
- Manual Operation Difficulty: Large component handling required multiple operators and increased coordination requirements.
Site Inspection and Expert Recommendation
Our engineering team conducted an on-site inspection at the customer’s wind power manufacturing facility to evaluate the workshop layout, transportation routes, operating environment, and component handling requirements.
During the inspection, the team reviewed the following conditions:
- Factory production layout and transportation paths;
- Weight and dimensions of large wind power components;
- Daily transportation frequency and working distance;
- Existing handling equipment and operation methods;
- Workshop safety requirements.
After conducting an on-site inspection, REMARKABLE’s engineers proposed using a 90-metric-ton explosion-proof AGV. Equipped with automatic navigation, a 90-metric-ton load capacity, and explosion-proof protection, this AGV is ideally suited for transporting heavy components within the workshop.
Provided Solution
REMARKABLE supplied a 90 Ton Explosion Proof AGV Transfer Cart for transporting heavy wind power components inside the workshop.
The AGV was customized with the following configurations:
- Load Capacity: 90 Ton
- Power Supply: Lithium Battery
- Drive System: Electric Drive
- Navigation System: Laser Navigation
- Control Mode: Automatic Control + Wireless Remote Control
- Steering Mode: Four-Wheel Steering
- Platform Size: Customized According to Components
- Safety System: Emergency Stop, Obstacle Detection, Safety Warning
- Explosion Proof Design: Explosion Proof Motor and Electrical Components
The AGV runs between welding, assembly, inspection, and storage areas to transport large wind power components. The customized platform and automatic navigation system allow the vehicle to operate according to the customer’s workshop layout.
Specifications
| Parameter | Specification |
| Load Capacity | 90 Ton (Customized: 10–300 Ton) |
| Platform Size | Customized according to load dimensions and transport requirements |
| Vehicle Structure | Heavy-duty welded steel frame with anti-corrosion treatment |
| Power Supply | Maintenance-free Battery / Lithium Battery |
| Driving System | Electric drive with independent wheel control |
| Drive Mode | Automatic AGV Driving |
| Navigation System | Laser SLAM / Magnetic Guidance / QR Code / Hybrid Navigation |
| Positioning Accuracy | Customized according to the navigation system and application requirements |
| Control System | PLC Control + Remote Control, Optional WMS/MES Integration |
| Communication Method | Industrial Wireless Communication / Customized |
| Safety Devices | Laser Scanner, Obstacle Detection, Emergency Stop, Audible & Visual Alarm |
| Explosion Proof Design | Explosion Proof Motors, Electrical Components, Battery Protection System |
| Explosion Proof Standard | Customized according to ATEX / IECEx / NEC / Local Hazardous Area Requirements |
| Handling Function | Transport / Lifting / Roller Conveyor / Customized Fixtures |
| Travel Speed | Customized according to load and working conditions |
| Operating Environment | Hazardous Industrial Areas, Indoor and Outdoor Applications |
| Working Temperature | Customized according to application environment |
| Charging Method | Automatic Charging / Manual Charging Options |
| Runtime | Customized according to Battery Capacity and Working Cycle |
Application Results
After the 90 Ton Explosion Proof AGV Transfer Cart was put into operation, the customer used the AGV for daily transportation of large wind power components between welding, assembly, inspection, and storage areas. The equipment handles 15–20 transportation tasks per day, with a single transportation distance of 80–150 meters and a maximum load capacity of 90 tons.
Compared with the previous forklift and crane handling method, the number of operators involved in each transfer was reduced by 50%, and the preparation time for heavy component transportation was reduced from 30–40 minutes to around 15 minutes, increasing transportation efficiency by approximately 50%.
The AGV has been running in the workshop for heavy component transfer, replacing manual coordination during repeated transportation operations and providing a stable handling method for large wind power components.
Applications
The 90 Ton Explosion Proof AGV Transfer Cart can be used for heavy load transportation in various industries.
Wind Power Manufacturing
Used for transporting wind turbine towers, nacelle structures, hub supports, and other large components.
Heavy Machinery Manufacturing
Used for moving large machine bases, equipment frames, and heavy fabricated parts between production areas.
Steel Structure Fabrication
Used for transporting steel structures, welded assemblies, and oversized metal components.
Shipbuilding Industry
Used for transferring ship sections, hull blocks, and large marine components inside workshops.
Automotive and New Energy Industry
Used for transporting battery packs, production equipment, and heavy assembly parts.
Aerospace Manufacturing
Used for moving large aircraft structures and precision components during manufacturing processes.
Metallurgy and Foundry Industry
Used for transporting molds, ladles, steel products, and heavy industrial materials.
Petrochemical Industry
Used for handling large vessels, tanks, and equipment modules in industrial plants.
REMARKABLE Customization
REMARKABLE provides customized AGV transfer carts based on load capacity, workshop conditions, transportation routes, and application requirements.
- Load Capacity: 10 Ton–500+ Ton
- Power System: Lead-Acid Battery, Lithium Battery, Cable Power Supply, Rail Power Supply
- Navigation System: Laser Navigation, Magnetic Navigation, QR Code Navigation, Customized Navigation System
- Vehicle Structure: Platform Size, Table Height, Wheel Configuration, Steering Mode, Drive System
- Control System: Automatic Control, Wireless Remote Control, PLC Control, Central Control System Integration
- Safety Configuration: Explosion Proof Design, Obstacle Detection System, Emergency Stop Device, Safety Warning System
- Application Fields: Wind Power Equipment, Heavy Machinery, Steel Structure, Shipbuilding, Metallurgy, Petrochemical Industry
For large component handling projects, REMARKABLE offers customized AGV transfer cart design, manufacturing, and technical support. Contact us for a suitable heavy load transportation solution for your factory.
FAQ
What is a 90 ton explosion proof AGV transfer cart?
A 90 ton explosion proof AGV transfer cart is an automated vehicle designed for transporting heavy industrial loads up to 90 tons in special working environments.
Why use AGV transfer carts in wind power manufacturing?
AGV transfer carts can transport large wind power components between production areas with automatic operation and flexible routing.
What loads can a 90 ton AGV transport?
It can transport heavy components such as wind turbine parts, steel structures, machinery bases, and large fabricated assemblies.
How does an explosion proof AGV work?
The AGV uses protected electrical components and safety systems to operate in environments requiring explosion proof protection.
Can the AGV route be customized?
Yes. Navigation routes, platform dimensions, and control systems can be customized according to factory layout.
What is the difference between AGV transfer carts and rail transfer carts?
AGV transfer carts use automatic navigation and do not require fixed tracks, while rail transfer carts move along installed rails.
Does REMARKABLE provide overseas AGV projects?
Yes. REMARKABLE provides customized design, manufacturing, and technical support for industrial customers worldwide.
How much load capacity can REMARKABLE AGVs provide?
REMARKABLE provides customized AGV transfer carts from several tons to over 100 tons according to application requirements.