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Carro elevador para baterías de vehículos eléctricos
Project description
Acres Engineering designed and manufactured a custom EV battery handling trolley for JLR, developed to support the safe transport, lifting and positioning of different battery pack configurations within the production facility.
The solution combines an adjustable lifting platform, dedicated support points and integrated locking and safety systems. Its design enables controlled handling of MLA, EMA and JEA battery architectures, improving operator ergonomics and efficiency throughout the process.
Client requirement
The customer required a custom material handling solution for moving and positioning electric vehicle batteries within the facility. Due to the size, weight and geometry of these components, a stable handling system was needed to support safe movement while reducing the risks associated with heavy-load handling.
The equipment needed to be compatible with different battery architectures while keeping each battery pack correctly supported and securely locked throughout the operation. It also required an adjustable working height to enable integration with other equipment and stages of the production process.
In addition, the design needed to provide suitable access for the existing lifting systems, prevent interference with the handling clamps and protect both the battery pack and the trolley’s painted surfaces during continuous industrial use.
Solution developed by Acres
Acres managed the complete development of the project, starting with an analysis of the different battery geometries, support points and real handling conditions within the production facility.
Our engineering team developed the mechanical and structural design of the trolley, creating a platform compatible with MLA, EMA and JEA battery architectures. The support layout was adapted to provide stable and repeatable positioning, with integrated locking points to secure the battery during movement and final positioning.
A central scissor lift system was incorporated to adjust the working height. The platform geometry was optimised to avoid interference with the lifting clamps, while the guidance and mobility system was configured to improve control during movement and positioning.
Acres was responsible for the manufacture of the steel structure, assembly of components, installation of supports and safety systems, final adjustment of the equipment and preparation of the manufacturing documentation.
The result is a robust and versatile EV battery lifting trolley, specifically developed to improve safety, ergonomics and efficiency when handling heavy battery packs in automotive production environments.
Technical design specifications
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Compatible with MLA, EMA and JEA battery architectures
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Capacity for handling one battery pack per operation
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Adjustable platform height from 750 to 1100 mm
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Central lifting system using a scissor mechanism
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Distributed nylon supports adapted to different battery geometries
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Integrated locking points to secure the load on the platform
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Polyurethane contact areas to protect painted surfaces
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Enlarged platform cut-outs to prevent interference with lifting clamps
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Integrated guarding around the scissor mechanism to improve operator safety
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Reinforced handle design to improve rigidity and reduce central flex
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Industrial polyurethane castors with a hardness of 92 Shore A
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Swivel castors with brakes and directional locks for easier manoeuvring and accurate positioning
Do you need a similar solution?
At Acres Engineering, we specialise in the design, manufacture and end-to-end management of industrial projects focused on improving component storage, protection and handling within production environments. We develop custom material handling equipment, including metal containers, racks, stillages, industrial trolleys and bespoke handling systems for the defence, aerospace, automotive, rail and wider manufacturing sectors.
We assess each requirement from the initial engineering and design stage through to manufacture and final delivery, adapting every solution to the load, production process and actual operating conditions.
