BAE Case Study — OmniDirectional Cart with High Maneuverability

The Situation: BAE approached Conceptual Innovations to developed an OmniDirectional Cart capable of carrying 40K lbs. of payload.  The cart needed to move the vehicle chassis in and out of weld cells.  These cells were situated in such a way that a high degree of maneuverability was required.  

Typically, vehicle movements from cell to cell are performed via an overhead crane which requires trained operators to perform the movement.  With limited crane capacity and operator availability, the entire process was becoming bottlenecked.

The Solution: Conceptual Innovation’s OmniDirectional Drive Pods were an ideal fit for this application. A complete turnkey cart (100″ wide by 250″ long) was developed that consisted of 4 Omni Directional drive pods and 4 load-bearing swivel-on-swivel 97 Series casters from Caster Concepts. 
All drive pods on the cart employ a suspension system that allows the drive wheels to maintain proper traction with the ground.

With the OmniDirectional cart in place to move the chassis, the operation was sped up, safety was improved, and movement is performed by general operators. Engineering the frame also included running detailed FEA on the structure to ensure it met a 5X Safety Factor on UTS.

The cart is battery powered and also features a wireless control pendent with a 3 axis joystick, fast and slow modes, and E-Stop.   The pendant contains a rechargeable LI-Ion battery. An onboard battery charging system that is power via standard 120VAC and can charge the batteries overnight.