Rail Transfer Trolley for Pipeline Welding with Hollow Structure Boosts Production Line Handling

A mechanical manufacturing company undertaking large scale pipeline welding projects faced frequent transportation of metal pipes with a diameter of 0.8 meters and a length exceeding 1.5 meters.

Traditional hoisting equipment was bulky, limiting operational space, and prone to deformation in high temperature welding environments. Manual trolleys lacked stability, risking pipe slips and severely impacting welding efficiency and safety.

Solution: Battery-Powered Rail Transfer Trolley

The workshop introduced a customized cast steel rail transfer cart, addressing challenges through the following structural designs and functional configurations:
 

1. High-Temperature-Resistant Cast Steel Structure for Welding Environments

• Frame and Wheels: The entire trolley is constructed from cast steel, resistant to temperatures up to 800°C to prevent deformation from welding spatter. Wheel surfaces are heat-treated, enhancing wear resistance with a service life 3 times longer than standard models.
• Hollow Table Design: The central hollow area (sized to fit pipe curvature) securely holds pipes, allowing welding debris to fall through naturally and preventing accumulation. Combined with two pairs of vertical rollers (drive wheels + idler wheels), it enables 360° smooth pipe rotation, eliminating the need for repeated angle adjustments during welding.

2. Wireless Remote Control + Emergency Stop Dual Safety System

• Wireless Remote Control: Operators can precisely control cart movement (forward/backward) and roller speed from 3 meters away, keeping them clear of high temperature zones.
• Audible-Visual Alarm + Emergency Stop Button: The device activates flashing warning lights and a siren upon startup. In emergencies, the emergency stop button halts operations in <0.5 seconds, reducing annual safety incidents by 90%.

3. Modular Body for Complex Scenarios

• Clamp-Style Split Structure: The rail transfer trolley quickly disassembles into two parts for transport through narrow passages. When assembled, it supports a 2-ton load, ideal for multi-pipe handling.
• Intelligent Power Management: A built-in screen displays real-time battery levels, paired with a portable charging station for on-demand quick charging to ensure 24-hour continuous operation.

Customer Feedback

“The wireless remote and emergency stop functions have eliminated safety hazards in the welding workshop, while the roller drive has significantly improved pipe alignment precision for welding points. The customizable split design was an unexpected bonus—adjusting body modules for different orders has exceeded our efficiency expectations!”
— Production Department Head, Mechanical Manufacturing Company